Robotic Programming for High-Mix Applications Robotic Programming for High-Mix Applications Greg Culp Software Sales Manager Hypertherm Robotic Software

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

Copyright 2016, Hypertherm, Inc. All rights reserved.

Industry Drivers

• Advances in manufacturing

Global Economy

Flexible Automation

Just-in-Time / Lean

Innovative new processes

▲ Performance, ▼Costs

ROI /Capital expenditures


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


PROGRAMMING BARRIERS

Programming Barriers

• Task dimension and machine tool kinematics

2D




3D




5X



• Tasks are commonly 2-5D



• Robots are typically 6D+

6X 7X 9X



• 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



• It is desirable to program a robot in Cartesian coordinates

• Robots are commanded in joint values by the robot controller



• 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



• Programs must be singularity free

• A six axis robot has three singularity zones



• A robot has 8 possible configurations for every point



• A variety of manufacturing processes (additive/subtractive/forming)



• A variety of manufacturing processes (additive/subtractive/forming)





• Robot off-line simulation and programming software

• More robot centered, less task focused



• CAD/CAM Software

• More path centered, less robot focused


2D Problem

• Dimensions of a solution are very important

2D INPUT

COLD WATER

HOT WATER

2D OUTPUT

FLOW

TEMPERATURE


2D Problem• Dimensions of a solution are very important


2D Problem

• Difficult user experience


TASK BASED PROGRAMMING

Task Based Programming

• Task and Device independence



• CASE: Trimming of knee brace

• BEFORE: Manual

• AFTER: Robotic

EXPERTISE REQUIRED?

Task/Process

Programming and CAD/CAM

Robotics and Simulation



• Easy robot programming



• Easy robot programming


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


Task Sharing

• Cooperative task sharing


Task Sharing



Task Sharing

• Optimized cooperative task sharing


Task Sharing



Task Sharing

• Task success is easy with the proper programming tools



• 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


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

Documents

Robotic Programming for High-Mix Applications Robotic Programming for High-Mix Applications Greg Culp Software Sales Manager Hypertherm Robotic Software