Robotic Programming for High-Mix Applications
Greg Culp
Software Sales Manager
Hypertherm Robotic Software
Automate 2017• Iconic Movie Theme
Composer
Monty Norman
Composed James Bond Theme song in 1962 for the film Dr. NO.
Automate 2017
Automate 2017
Robotic Software “Mindshift”
• Perception of Robotic Software needs to change.
• Dedicated Robotic Software Development Companies.
• One Platform for Multiple Applications.
Table of Content
Table of Content
• Drivers for high-mix low-batch production
• Robot programming barriers
• Task based programming
INDUSTRY DRIVERS
Industry Drivers
• New robotic markets emerging
• Milling and trimming
• Cutting (laser, plasma,
waterjet)
• Welding
• Painting, spraying,
dispensing
• Polishing, grinding,
sanding
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Industry Drivers
• Advances in manufacturing
Global Economy
Flexible Automation
Just-in-Time / Lean
Innovative new processes
▲ Performance, ▼Costs
ROI /Capital expenditures
Copyright 2016, Hypertherm, Inc. All rights reserved.
Industry Drivers
• New robotic markets emerging
“The model company is no longer a large entity such as GM, Chrysler, or
Ford but small and medium sized enterprises…. The need in such an
economy is far more dependent on higher degrees of adaptation, ease of
use, and other factors that enable small runs of made-to-order products.”
Roadmap to the Future by Paul Kellett,
RIA Director - Market Analysis
Industry Drivers
• Hardware capability is almost there
Industry Drivers
• Programming robots is very different than a CNC machine tool
Program
Teach
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PROGRAMMING BARRIERS
Programming Barriers
• Task dimension and machine tool kinematics
2D
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Programming Barriers
• Task dimension and machine tool kinematics
3D
Copyright 2016, Hypertherm, Inc. All rights reserved.
Programming Barriers
• Task dimension and machine tool kinematics
5X
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Programming Barriers
• Tasks are commonly 2-5D
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Programming Barriers
• Robots are typically 6D+
6X 7X 9X
Copyright 2016, Hypertherm, Inc. All rights reserved.
Programming Barriers
• A typical 6 axis robot only has rotary axis
• Joint limits are hard to check
intuitively
• Robot to part collision is
impossible to determine
without simulation
• Reach is difficult to check
Copyright 2016, Hypertherm, Inc. All rights reserved.
Programming Barriers
• It is desirable to program a robot in Cartesian coordinates
• Robots are commanded in joint values by the robot controller
Copyright 2016, Hypertherm, Inc. All rights reserved.
Programming Barriers
• A 6 axis robot requires position and orientation for each point
(X,Y,Z),(I,J,K)
• Tasks are typically 2-5D
• Managing 6D pose is required
Copyright 2016, Hypertherm, Inc. All rights reserved.
Programming Barriers
• Programs must be singularity free
• A six axis robot has three singularity zones
Copyright 2016, Hypertherm, Inc. All rights reserved.
Programming Barriers
• A robot has 8 possible configurations for every point
Copyright 2016, Hypertherm, Inc. All rights reserved.
Programming Barriers
• A variety of manufacturing processes (additive/subtractive/forming)
Copyright 2016, Hypertherm, Inc. All rights reserved.
Programming Barriers
• A variety of manufacturing processes (additive/subtractive/forming)
Copyright 2016, Hypertherm, Inc. All rights reserved.
Programming Barriers
Copyright 2016, Hypertherm, Inc. All rights reserved.
Programming Barriers
• Robot off-line simulation and programming software
• More robot centered, less task focused
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Programming Barriers
• CAD/CAM Software
• More path centered, less robot focused
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2D Problem
• Dimensions of a solution are very important
2D INPUT
COLD WATER
HOT WATER
2D OUTPUT
FLOW
TEMPERATURE
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2D Problem• Dimensions of a solution are very important
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2D Problem
• Difficult user experience
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TASK BASED PROGRAMMING
Task Based Programming
• Task and Device independence
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Task Based Programming
• CASE: Trimming of knee brace
• BEFORE: Manual
• AFTER: Robotic
EXPERTISE REQUIRED?
Task/Process
Programming and CAD/CAM
Robotics and Simulation
Copyright 2016, Hypertherm, Inc. All rights reserved.
Task Based Programming
• Easy robot programming
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Task Based Programming
• Easy robot programming
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TASK SHARING
STRICTLY CONFIDENTIAL – FOR INTERNAL USE ONLY
SOURCE: http://video.bonappetit.com/watch/jacques-pepin-peels-an-apple
Task Sharing
Holder arm
Worker arm
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Task Sharing
• Cooperative task sharing
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Task Sharing
• Cooperative task sharing
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Task Sharing
• Optimized cooperative task sharing
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Task Sharing
• Cooperative task sharing
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Task Sharing
• Task success is easy with the proper programming tools
Copyright 2016, Hypertherm, Inc. All rights reserved.
Programming Barriers
• Kinematics and Robotics (Hyper real-time calculations)
• Mathematical Optimization (AI, Deep/Machine Learning)
• Simulation and User Interaction (Collisions)
• CAD/CAM (Easy task based programming)
• Technology paradigm shift = Multi-disciplinary team
Software Engineering
Copyright 2016, Hypertherm, Inc. All rights reserved.
Greg CulpSenior Software Sales Manager
Robotmaster (Hypertherm Inc.)21 Great Hollow Rd
Havover, NH
USA
Telephone: 630-643-3441 ext. 3014
Email: [email protected]
www.robotmaster.com