6
An Automated Path Laser Scanner for Jens Hatwig, Pasc Institute for Boltz Abstract - Remote laser beam welding (R laser beam cutting (RLC) are technologies that a automated applications in industrial faciliti contactless mode of action. The main adv processes are the high operation speed, good pr a tailored contour of the welding seams and cut optimal use of these processes the laser beam accurately over the work piece. A common tec of such processes is the combination of a laser unit, a laser scanner and an industrial ro represents a programming challenge, as the freedom of the robot plus the two degrees of fre scanner lead to a kinematic redundant syste advantages of this combination, the large robo the fast and precise motion of the laser scanne attractive technology for improvement of wel processes. An automated programming system setup is presented in this paper. Time Optimal Robot Path - Redundant System - C Different Systems I. INTRODUCTION The implementation of remote laser manufacturing promises many advantages, a flexible, contactless and abrasion free tool. Es the-fly” motion of an industrial robot combi scanner (see Fig. 1) can increase the process s of 3-10 compared to resistant spot welding achieve this required functionality, the path p to be automated. In this paper an automat system is presented. Firstly, the motivation f this system is derived from the characteristic laser processes. Then, the new path plannin described in detail. Finally the description o programming of the robot and the laser production of a heat exchanger device is discu A. Remote Laser Beam Welding and Cutting: Description A laser beam source can be used to perfo on a work piece without the need to repl hardware components [2]. Only process p between welding, marking and cutting, wh speed of the laser beam on the work piece, th focus and the power of the laser beam amongs h Planning System for a Ro Remote Laser Cutting and cal Minnerup, Michael F. Zaeh and Gunther Reinhar r Machine Tools and Industrial Management (iwb) Technische Universitaet Muenchen zmannstraße 15, 85748 Garching, Germany [email protected] RLW) and remote are well suited for ies due to their vantages of both rocess quality and tting kerfs. For an has to be guided chnical realization r beam deflection obot. This setup e six degrees of eedom of the laser em. However, the ot workspace and er make it a very lding and cutting for the described Combination of processes into as the laser is a specially the “on- ined with a laser speed by a factor [1]. However, to planning task has tic programming for implementing cs of the remote ng algorithms are of the automated scanner for the ussed. Process orm several tasks lace or add any parameters differ hich include the e diameter of the st others. For an Fig. 1 Remote laser welding and cuttin and a laser scan adequate path planning for the robo essential that the speed of the lase remains constant which directly process quality. This is challenging fly motion. For an understandin algorithm introduced in this work, b briefly described. 1) Remote Laser Beam We becoming the main welding tec production. Daimler AG was one used this innovative process with combination to improve the manuf In order to call the process RLW, laser beam forming optics and the w 300 mm, but it can reach up to sev collision is minimized by the large d and the work piece. Moreover, the l motion of the laser beam on t movements of the robot translates laser beam. Hence, process speeds work piece are possible [4]. More stays stable up to inclination an Therefore, the laser beam does not guided over the work piece. This utilized for an optimized path plann obot with a d Welding rt ng system with an industrial robot nner. ot and the laser scanner it is er beam on the work piece y translates into constant g especially for an on-the- ng of the path planning both RLC and RLW will be elding: RLW is slowly chnology in high volume of the first companies that a robot and laser scanner facturing of car bodies [3]. , the distance between the work piece must be at least eral meters [4]. The risk of distance between the optics long distance enables a fast the work piece as small to large movements of the of about 200 mm/s on the eover, the welding process ngles of about ±20° [5]. need to be perpendicularly degree of freedom can be ning. 1323 978-1-4673-1278-3/12/$31.00 ©2012 IEEE Proceedings of 2012 IEEE International Conference on Mechatronics and Automation August 5 - 8, Chengdu, China

[IEEE 2012 IEEE International Conference on Mechatronics and Automation (ICMA) - Chengdu, China (2012.08.5-2012.08.8)] 2012 IEEE International Conference on Mechatronics and Automation

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Page 1: [IEEE 2012 IEEE International Conference on Mechatronics and Automation (ICMA) - Chengdu, China (2012.08.5-2012.08.8)] 2012 IEEE International Conference on Mechatronics and Automation

An Automated PathLaser Scanner for

Jens Hatwig, PascInstitute for

Boltz

Abstract - Remote laser beam welding (Rlaser beam cutting (RLC) are technologies that aautomated applications in industrial faciliticontactless mode of action. The main advprocesses are the high operation speed, good pra tailored contour of the welding seams and cutoptimal use of these processes the laser beam accurately over the work piece. A common tecof such processes is the combination of a laserunit, a laser scanner and an industrial rorepresents a programming challenge, as thefreedom of the robot plus the two degrees of frescanner lead to a kinematic redundant systeadvantages of this combination, the large robothe fast and precise motion of the laser scanneattractive technology for improvement of welprocesses. An automated programming system setup is presented in this paper. Time Optimal Robot Path - Redundant System - CDifferent Systems

I. INTRODUCTION

The implementation of remote laser manufacturing promises many advantages, aflexible, contactless and abrasion free tool. Esthe-fly” motion of an industrial robot combiscanner (see Fig. 1) can increase the process sof 3-10 compared to resistant spot welding achieve this required functionality, the path pto be automated. In this paper an automatsystem is presented. Firstly, the motivation fthis system is derived from the characteristiclaser processes. Then, the new path plannindescribed in detail. Finally the description oprogramming of the robot and the laser production of a heat exchanger device is discu A. Remote Laser Beam Welding and Cutting: Description

A laser beam source can be used to perfoon a work piece without the need to replhardware components [2]. Only process pbetween welding, marking and cutting, whspeed of the laser beam on the work piece, thfocus and the power of the laser beam amongs

h Planning System for a RoRemote Laser Cutting and

cal Minnerup, Michael F. Zaeh and Gunther Reinharr Machine Tools and Industrial Management (iwb)

Technische Universitaet Muenchen zmannstraße 15, 85748 Garching, Germany

[email protected]

RLW) and remote are well suited for ies due to their vantages of both rocess quality and tting kerfs. For an

has to be guided chnical realization r beam deflection obot. This setup e six degrees of eedom of the laser em. However, the ot workspace and er make it a very lding and cutting for the described

Combination of

processes into as the laser is a specially the “on-ined with a laser speed by a factor [1]. However, to planning task has tic programming for implementing cs of the remote

ng algorithms are of the automated scanner for the

ussed.

Process

orm several tasks lace or add any

parameters differ hich include the e diameter of the st others. For an

Fig. 1 Remote laser welding and cuttinand a laser scan

adequate path planning for the roboessential that the speed of the laseremains constant which directlyprocess quality. This is challengingfly motion. For an understandinalgorithm introduced in this work, bbriefly described. 1) Remote Laser Beam Webecoming the main welding tecproduction. Daimler AG was one used this innovative process with combination to improve the manufIn order to call the process RLW,laser beam forming optics and the w300 mm, but it can reach up to sevcollision is minimized by the large dand the work piece. Moreover, the lmotion of the laser beam on tmovements of the robot translates laser beam. Hence, process speeds work piece are possible [4]. Morestays stable up to inclination anTherefore, the laser beam does not guided over the work piece. This utilized for an optimized path plann

obot with a d Welding rt

ng system with an industrial robot nner.

ot and the laser scanner it is er beam on the work piece y translates into constant g especially for an on-the-ng of the path planning both RLC and RLW will be

Welding: RLW is slowly chnology in high volume of the first companies that a robot and laser scanner

facturing of car bodies [3]. , the distance between the work piece must be at least eral meters [4]. The risk of distance between the optics long distance enables a fast the work piece as small to large movements of the of about 200 mm/s on the

eover, the welding process ngles of about ±20° [5]. need to be perpendicularly degree of freedom can be

ning.

1323978-1-4673-1278-3/12/$31.00 ©2012 IEEE

Proceedings of 2012 IEEEInternational Conference on Mechatronics and Automation

August 5 - 8, Chengdu, China

Page 2: [IEEE 2012 IEEE International Conference on Mechatronics and Automation (ICMA) - Chengdu, China (2012.08.5-2012.08.8)] 2012 IEEE International Conference on Mechatronics and Automation

A few programming methods have beeprogram the system with an on-the-fly mosystem described in [3] uses a master PC torobot and the laser scanner during the processgets the position of the robot and calculates tthe mirrors of the laser scanner in the internal robot. In another approach, the robot path andlaser scanner are generated before the processcontrolled by a dedicated external controoperates the laser scanner. The robot path is tstandard robot controller unit. Both systems in industrial RLW applications. A remote without laser scanners is presented in [4]. Tguided over the work piece solely by the robot 2) Remote Laser Beam Ablation CuttingRLW remote laser beam cutting is a new pryet widely used in industrial manufacturingprocess has a great potential to improve thprocess speeds of up to 6,000 mm/s are possibdiameter of 50 μm the material is partly resulting gas pressure is used to force the moof the cutting kerf. This cutting process is removal of the material, about 50-100 μm perlaser beam are ablated. The layer by layer remeffective cutting speed depending on the thickpiece [2]. These latter two aspects reprdifferences between RLW and RLC. To process the working field of the laser scasituated exactly in the same layer as thTherefore, the inclination angles are limited of the laser scanner. A maximum of about 20° The lack of an intuitive or automated procombined system of the laser scanner and theis one reason for the difficulties to apply thindustrial manufacturing [7]. B. System Setup For reaching process speeds of more thanuse of laser scanners is obligatory. This laserdevice consists of two mirrors to position theseveral lenses to focus the laser beam on thethe mirrors have a low mass and therefore a laser scanner can guide the laser beam faster aprecision over the work piece than an indulaser scanner has a working field of around 3a distance of 400 mm. In the project descriscanner from Arges GmbH (Welding Elephanan industrial robot from Reis GmbH & Co. KGorder to validate the flexibility of the programwas also tested with another robot (KR60 HGmbH). The laser beam source is a 3 kW silaser from IPG GmbH. Today, this laser beaonly one on the market which has sufficient br[2]. The whole system setup is shown in Fdifference in the controls of both systems is ttime. The laser scanner operates at 10 μs, wrobots operate at more than 1 ms.

en introduced to otion [3, 6]. The synchronize the s. The master PC the deflection for cycle time of the d the task for the s (offline) and are oller [6] which transferred to the are already used welding system

he laser beam is t. g: In contrast to rocess that is not g. However, this he cycle time, as ble. With a focus

vaporized. The olten material out a layer by layer r exposure of the moval leads to an kness of the work resent the main

implement this anner has to be he work piece. to the deflection

° is reachable. ogramming of the e industrial robot is process to the

n 6,000 mm/s the r beam deflecting e laser beam and e work piece. As small inertia the

and with a higher ustrial robot. The 300 × 300 mm2 at ibed here a laser nt) is mounted to G (RV 60-60). In mming system it

HA from KUKA ingle mode fibre am source is the rilliance for RLC

Fig. 1. One main the internal cycle

whereas industrial

C. Problem Definition There are several commercial RLW that have already proved theHowever, higher operation speedsparameters like multiple exposures require new path planning strategies

An automated path plannincombined motion of the robot and tmanually programmed at the requiradversely affecting process qualitpath should be optimized with respThe cycle time can be reduced toproductive process time, the laser of

Additionally, in small and meexpert for programming industriavailable and the expert for the welhas to be able to program the cTherefore, the programming systusable.

II. GENERAL ASSUMPTION

For the application of remote programming is a convenient tool t8]. Using this programming methodinstead of the motion of the robot.description contains the geometric seams and cutting kerfs. Normallycoordinate frame to use the repeataof the absolute accuracy. If the gathered from CAD data, best fit position the task with respect to thehand the process parameters are geometric information. Once theplanning system can generate the laser scanner using the process para A. General Assumptions and Simplif The used system setup has a febe regarded. Therefore, the folsimplifications are made.

Fig. 2 Working field of

path planning systems for eir application in industry. s and further new process of the cutting kerf at RLC

s [7]. ng is obligatory, as the the laser scanner cannot be red process speeds without ty. Furthermore, the robot pect to the total cycle time. o a minimum, if the non-ff time, is minimized [8]. edium sized enterprises an ial robots is not always lding and cutting processes utting and welding robot. tem has to be intuitively

NS AND CONCEPT

processes, a task oriented to program a robot [2, 4, 6, d the task itself is described . On the one hand the task information of the welding

y, this is done in the robot ability of the robot instead geometric information is programs can be used to

e robot [6, 9]. On the other stored together with the

e task is defined a path path for the robot and the

ameters.

fications ew restrictions that have to llowing assumptions and

f the laser scanner.

1324

Page 3: [IEEE 2012 IEEE International Conference on Mechatronics and Automation (ICMA) - Chengdu, China (2012.08.5-2012.08.8)] 2012 IEEE International Conference on Mechatronics and Automation

Both, the cutting kerfs and the welding seas subtasks in this paper. However, in terplanning algorithm there is no difference betw The working field of the laser scanner circle. The corners are neglected (see Fig. 2). Afield is easier to handle, as the working fiscanner can be described using only the radiucircle and the position of its center. The centethe tool center point of the robot. This canquality of the process diminishes as the inclin[4]. Therefore, the maximum inclination angin every direction. The inclination can alsoreducing the radius, e.g. if the accessibility is subtasks because of the clamping device. The path of the robot has to be known inprograms of the robot and the laser scanner ruon their controllers [8]. Due to the high procesrequired accuracy at multiple exposures withdiameter the robot guides the laser scanner o(LIN-movement) over the work piece whprogress. Short delays for starting the laserrobot would result only in a displacemencorresponding subtask. If the robot moves spline curve and the start of the laser scanner cannot be performed, as the geometric shapeswill not correspond to each other anymore. Awork piece and the working field of the scaexactly. The focus of the laser beam has to ranges in the direction of the laser beam oninside the so called Rayleigh-Length [2, 4, 5, deflect the laser beam, the scanner updates thso that the focus stays in one area (see Fig. 2LIN-movement has to be parallel to the workthe complexity of the path planning is reproblem. As the robot has a 3D workspace andoes not need to lie horizontally, the whole sy2,5D work pieces with the same programmingas each subtask lies solely in one planar layersubtasks that fit slightly curved layers, the lasrefocus the laser beam on the work pieprogramming strategy can be used for 3D wand the reduction does not eliminate any solut B. Concept for the Path Planning Algorithm The calculation of the path for the robofive steps according to the concept shown in planning for the robot (step 3) is the main cpath defines the cycle time to process the work 1) First Step: The task is analyzed in othe size of the task, the number of the suprocesses and the dimension of the task. Thused in the following steps to generate the paand the laser scanner. 2) Second Step: Based on the characterissuitable system setup is recommended. The increased by solely moving the minimum numare necessary to manufacture the work piece.

eams are denoted rms of the path

ween them. is reduced to a

A round working ield of the laser

us of the resulting er of the circle is

n be done as the nation angles rise gles are the same o be limited by limited for some

n advance, as the un synchronously ss speeds and the h a 50 μm focus on a straight line hile RLC is in r scanner by the nt of the whole on a circle or a is delayed, RLC

s of both systems Additionally, the anner have to fit remain in small

n the work piece, 7]. If the mirrors

he focus distance 2). Therefore, the k piece. Thereby educed to a 2D nd the work piece ystem can process g strategy as long r. For processing

ser scanner has to ece. Hence, the work pieces, too, tion.

ot is divided into Fig. 3. The path

challenge, as this k piece.

order to calculate ubtasks, the used his information is aths for the robot

stics of the task a accuracy can be

mber of axes that

Fig. 3 Concept for the path plann

3) Third Step: The path for threspect to the task and the systempaper lies on the path planning for the main challenge for an optimal cy 4) Fourth Step: Having computhe task for the laser scanner can beonly using geometric transformation 5) Fifth Step: The last step contthe control. Two postprocessors, onone for the robot, are used to transfreadable programs. The robot is thethe laser scanner. Both programs stin order to machine the work piece.

III. NEW APPROACH FOR THE AUTFOR REMOTE LASER B

Using the described concept path planning for the robot. A new aover the work piece is presented in t

A. Calculation of the Robot’s Motio In this section the calculation ois derived of a given welding andaccording to the presented conpurposes, the path planning is showa heat exchanger device (see Fig. have to be cut into two plates, whabout 1000 × 500 mm2 each. Thermoved while processing the work holes have a diameter of 120 mmplates is 0.7 mm. The path plannfundamental steps.

Fig 4: Cutting of a heat exchanger plate (lewelding process (

5

Analysis of the welding and cuIdentification of its size and the used

Allocation of the task to differeMoving axes as sparse as possible

Calculation of the path of the Sorting the order of the subtasksOptimization of the robot’s path in re

Calculation of the resulting paImplementation of the controlSynchronously program flow on cor

4

3

2

1

Cycle time optimized robot and lfor remote laser beam wel

ning for remote laser cutting.

he robot is generated with m setup. The focus of this the robot, which represents ycle time. uted the path of the robot, calculated. This is done by n. tains the implementation of ne for the laser scanner and form the paths into machine e master system and it starts tart running synchronously

TOMATED PATH PLANNING EAM CUTTING

the main challenge is the approach to guide the robot this chapter.

on f the robot’s motion, which

d cutting task, is described ncept. For demonstration

wn for the manufacturing of 1 and Fig. 4). Eight holes hich have a dimension of refore, the robot has to be pieces. The circular typed

m and the thickness of the ning is divided into three

eft) and results of the cutting and (right).

utting taskd processes

ent positioning systems

robot

espect of the cycle time

ath of the laser scanner

rresponding controls

aser scanner programs lding and cutting

1325

Page 4: [IEEE 2012 IEEE International Conference on Mechatronics and Automation (ICMA) - Chengdu, China (2012.08.5-2012.08.8)] 2012 IEEE International Conference on Mechatronics and Automation

Fig. 5 Definition of the “Scan Circ

1) Scan Circles: At first the valid positscanner above each subtask are defined. Fcomputation this area is described in a circFig. 5). In the following, the biggest circle thintersection area will be called the “Scancorresponds to the area from which the laoperate. Therefore, the smallest circle, which subtask, is calculated. The corresponding derived from the position and size of the subof the working field of the laser scanner. If thecircle, a deviation between the Scan Circlpositions occurs. Additionally, in case the sizis small compared to the working field of the lrelative error is insignificantly small. Having nearly fill in the whole working field of the laScan Circles for two different directions cmanually in the task description to compensaThis needs to be done for very specialized task Hence, the subtasks that have to be prepresented as a set of circles that the lasercover during operation. The resulting path of represented by a straight line through these Sc 2) Generation of the Initial Robot Path: to find straight lines in a two dimensional spawith all scan circles defined in the task. Tsorted so that passing all center points of tleads to the shortest way (Traveling SalesmanIn order to get the initial path of the robot, thestraight line is placed at the center of the first direction is pointed to the middle of the secoWith the so called End Function (this functiothe next section) further Scan Circles are addline. If a subtask cannot be added, a new linlines are connected with a fast point-to-point mmovement) of the robot. For the cutting outs of the heat exchainitial lines are computed (see Fig. 6). The selaser is operating, are placed at the first posthe straight line. Thereby, the laser scanner hin each Scan Circle long enough to process thsubtask. The processing time TSubtask of eachcalculated out of its length lSubtask, its process its number of exposures n, according to (1).

cle”.

tions of the laser For an analytical cular shape (see

hat fits into the n Circle”, as it aser scanner can covers the whole Scan Circle is

btask and the size e subtask is not a le and all valid ze of the subtask laser scanner, the the subtasks that

aser scanner, two can be declared ate the deviation. ks, only.

processed can be r scanner has to

f the robot can be can Circles.

The next task is ace that intersect

The subtasks are the Scan Circles

n Problem). e start of the first Scan Circle. The ond Scan Circle.

on is described in ded to the straight ne is started. All movement (PTP-

anger plates two ections, when the sible position on

has to stay inside he corresponding h subtask can be speed vProcess and

Fig. 6 Initial path through the Scan Circle

vl

Tocess

SubtaskSubtask

Pr

=

The lengths of these “laser on” sectand the speed of the robot vRobot (2).

SRobotSection Tvl ⋅=As TSubtask is given by the procchangeable, lsection can be varied ontakes place, which ensures that everon the initial robot’s path. Expercannot exceed 200 mm/s for RLC, akerf quality until the process brvibrations of the robot. With this initial robot path processed, if the task for the stransferred to the controllers accordthe concept. The cycle time for the not considered, yet. 3) Path Optimization: The optiis only demonstrated for the first fopath of the robot leads to the shortetask, as the process time cannot visualization of the method the subfrom one line, as shown in Fig. 7more difficult to solve. Calculatiexchanger plates is easier, as allstraight line. For the algorithm presented convenient to use the direction of coordinate frame. Thereby the y didirection as the straight line of thethe whole computation process directions. Therefore, in each reknown. The corresponding x value called offset. The path of the robotend point, only. Now, the laser on their start points (y value) and lsection

es of the heat exchanger plates.

ns

(1)

tions are defined by TSubtask

Subtask (2) cess and is therefore not nly by vRobot. An adjustment ry subtask can be processed riments showed that vRobot as higher speeds reduce the reaks down, due to high

the work piece can be scanner is calculated and ding to step four and five of whole process, however, is

imization of the cycle time our subtasks. Shortening the est cycle time for the whole

be changed. For a better btasks have been displaced 7. This makes the problem ing the path for the heat l the subtasks lie on one

in this paper it is more the robot path in a rotated irection points in the same robot. This is possible, as

is repeated for several epetition the direction is in this coordinate frame is

t is defined by its start and sections can be defined by

n.

1326

Page 5: [IEEE 2012 IEEE International Conference on Mechatronics and Automation (ICMA) - Chengdu, China (2012.08.5-2012.08.8)] 2012 IEEE International Conference on Mechatronics and Automation

Fig. 7 Optimization method; End Function (left), Start Function and final pa

To optimize the length of the robot path of the sections on it three functions are necFunction (EF), the Start Function (SF) aFunction (LF). The EF defines the first possible end offor each offset. First possible end means the lvalue. The corresponding SF tells the last posstraight line that allows processing all reaching the y value of the EF. Using the SFcan compute the Length Function. It yields foffset the length of the resulting robot path. The calculation of EF is shown in Fig. 7When starting as early as possible, the first Scan be finished at the first arch (Arch1). The dthe SC1 and the Arch1 is lSection1. The possiwhole width of SC1, as Arch1 depends on precondition for this operation is an arch thawith SC1 (3).

∞−=0Arch (3) The second arch (Arch2) depends on SCshows the first possible points in which procesubtask can be completed. In general, Archpoints after processing subtask i can be compu

(

��� <

=

+= −

elseundefinedxSCBWifxSCBW

xArch

xlSCxArchxSCBW

iii

iii

,)(),(

)(

)();(max)( 1

In (4) lSCi is the lower half of the Scan Cupper half and li is the length of the procesubtask i. The End Function is the last Arcdefined for the valid offsets.

( mmin ,),()(max

xxxxArchxEF i ∈=

ath (right).

and the positions cessary: The End and the Length

f the straight line lowest possible y ssible start of the subtasks before and the EF, one for each possible

7 on the left side. Scan Circle (SF1) distance between ible offset is the

SC1, only. The at cannot interact

C2 and Arch1. It essing the second hi that shows the uted as:

)<+

xuSCl

i

i

)( (4)

Circle, uSCi is the essing section of ch (5), which is

)max (5)

Fig. 8 Cycle time optimal path th

The calculation of EF is shownWhen starting as early as possible, can be finished at the first arch (Arthe SC1 and the Arch1 is lSection1. whole width of SC1, as Arch1 deprecondition for this operation is awith SC1 (3). After knowing EF and SF one in (6). It is piecewise differentiable by adding or subtracting piecewise d

)( EFxtionLengthFunc = Therefore, the minimum of which is the optimal offset. In FiOptimized Robot Path. Using this optimal offset, the fThe straight line starts at SF(offset)in the rotated coordinate frame of line in the coordinate frame of Fig. the initially specified direction. After all previous calculations, value left: the direction. In this isampling is utilized. Systematicallymeans to try a number of equallydirection and use the best resultHaving calculated the best dirtransformed to the 3D path used forpath for the robot is shown is Fig. 8 B. Calculation of the resulting path As soon as the optimal robot pthe scanner can be easily calgeometrical transformation. As shocomplex movement, it is obviprogramming of the two devices ioutright impossible [8]. C. Implementation of the Control A standard industrial robot anare used for implementing RLC hardware and hence no extra progrthe costs are reduced compared to [3 The controllers of the robot andASCII coded programs in theirlanguage. Therefore, the calculattransformed into a robot program vto the controller. The same is do

hrough the scan circles.

n in Fig. 7 on the left side. the first Scan Circle (SF1)

rch1). The distance between The possible offset is the

epends on SC1, only. The an arch that cannot interact

can compute LF as shown because it has been created differentiable functions.

)()( xSFxF − (6) LF(x) can be computed,

ig. 7 this is shown by the

final straight line is created. ) and finishes at EF(offset) Fig. 7. To get the straight 6, it is rotated according to

there is only one necessary implementation systematic y sampling in this context

y distributed values for the t created by this method. rection the 2D path is r the actual robot. The final .

h of the laser scanner path is known, the task for lculated using a simple own in Fig. 9, due to the ious that manual online is very complicated if not

nd a standard laser scanner and RLW. As no extra

ramming effort are needed, 3, 6]. d the laser scanner can read r respective programming ted path of the robot is

via a postprocessor and sent one for the tasks of the laser

1327

Page 6: [IEEE 2012 IEEE International Conference on Mechatronics and Automation (ICMA) - Chengdu, China (2012.08.5-2012.08.8)] 2012 IEEE International Conference on Mechatronics and Automation

Fig. 9 Resulting path for the laser scanner.

scanner. The advantage of this procedure is the utilization of the standard and proved control systems of the robot and the laser scanner. This makes the system more acceptable in an industrial application compared to solutions which utilize their own custom-built programming interfaces. In this system setup the robot is considered as the master that starts the laser scanner once the robot reaches the first subtask. Then, both systems run synchronously until one straight line has ended. The robot restarts the laser scanner for each straight line movement. Thereby, the systems stay synchronous during the processing of the whole task. D. Applying the Concept to a Heat Exchanger Device The described programming method is demonstrated for manufacturing of a heat exchanger device. The programming of the whole system is reduced to teach the center points of the eight cut outs and of the two circular shaped welding seams. The circles were generated using predefined functions, which only need the center and the radius as input parameters. The large welding seam can be converted from CAD data to the task oriented programming using a best fit algorithm [6, 9]. Having the task description of the heat exchanger device, the programs for the robot and the laser scanner were generated automatically according to the described concept. After transferring the programs to the corresponding controllers the heat exchanger can be correspondingly machined.

III. CONCLUSION AND OUTLOOK

Remote laser beam processing is a promising technology to improve the automation and quality of several manufacturing processes. Reduction of the process cycle time and the complexity of the programming are the main challenges that have to be overcome for an application of these processes. However, the combination of an industrial robot and a laser scanner leads to this conflict. The laser scanner is necessary to shorten the process auxiliary time, but raises the complexity of the whole system.

In this paper a concept was presented for the automated programming of an industrial robot and a laser scanner for remote laser beam cutting, using task oriented programming. The implementation of the concept was demonstrated for a common work piece: a heat exchanger device. Applying this concept the advantages of the robot and the laser scanner are combined to process the work piece. This system can be used for subtasks that are smaller than the working field of the laser scanner, yet. If it exceeds the working field, two different strategies can be applied. At RLW a combined motion of the robot and the scanner can be realized [3, 6]. At RLC the robot is too slow. Therefore, the cutting kerf has to be divided into several cutting kerfs that fit into the working field. Up to now laser beam sources that can be used for RLC are still very expensive and programming systems for RLC with an on-the-fly motion have been tested in laboratory environments, only. To apply RLC into the manufacturing the described concept should be implemented into a fully integrated system controlling the robot and the laser scanner. This is necessary to meet the safety requirements of industrial manufacturing.

ACKNOWLEDGMENT

The results presented in this paper were gathered within the research project RoboLaSS, Roboter geführter Laser zum Schweißen und Schneiden (Robot guided laser for welding and cutting), funded by the German Federal Ministry of Education and Research (BMBF) and attended by Verein Deutscher Ingenieure e.V. (VDI).

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