Robot Simulation

A Tool For Project Success

Charles C. Gales, P.E.
Manager, Automation Sales
Weldon Solutions
Definition

sim - u - la - tion
The activity of producing conditions which are similar
to real ones, especially in order to test something, or
the conditions that are produced.

Source: ldoceonline.com
Robot Simulation Historical Perspective
Early 1990s, High End Work Stations produced marginal
results.
Robot Models (RobCad, Delmia, Process Simulate) were not precise.
Each simulation software manufacturer emulated Robot motion system
and performance.
Cycle times and Robot paths did not match the real world.
Required significant rework to match actual system to design
requirements.
Garbage in Garbage out
Realistic Robot Simulation
Initiative of:
Automotive Companies
Robot Manufacturers
Simulator Manufacturers
Line Builders
Measurement System Manufacturers
For Enhancing
Robot Simulation Accuracy
Robot Off-Line Programming
Methodology

Source: realistic-robot-simulation.org
RRS-1, Robot Controller Simulation (RCS)
RCS Interface
Original Motion Control Software
Developed as a Call Library
Call Library Provided For Groups,
Such As:
Interpolation
Transformation
Kinematics Cell Modeling
Machine Data
External Axes
Conveyor Synchronization
Event Generation Robot Path Deviation
Error Messages
Source: realistic-robot-simulation.org
RRS-2, Virtual Robot Controller (VRC)
VRC Interface
Near Complete Integration of Robot
Controller Software Into Simulation
Six Categories of Services
Real Controller Interface
I/O Communication
File System Transfer
User Interface
Virtual Controller Interface
Base Commands
Time Management
Simulator Support

VRC Functional Groups

Source: realistic-robot-simulation.org
 Where Do I Start?
Balance These Robot Parameters: Balance
Payload
Reach
Speed
Robots Are Generally Rated By Payload.
If Robot Has Payload Capacity, Will It Have
Enough Reach?
If Robot Has Payload Capacity, Will It Have
Sufficient Speed?
Payload Speed
Robot Simulation Can Answer
Questions To Help Balance Robot Reach
Selection
Case Study Machine Tending Workcell
SHAVER

OUTFEED
CHAMFER

INFEED
INSPECT

HOB
LATHE

PART
MARK
Machine Tending Workcell Robot Work Envelope
Design With 3D Model

Difficult To Position
Robot With CAD Software
Robot Simulation
 Installed System

In / Out Conveyors Lathe Part Marker

Installed System

Hob Chamfer Shaver

How Do I Do It?
Layout Investigation Program Generation Verification
Library
Layout Programming Simulation
Robot
2D layout import CAD-to-Path Cycle time
Layout creation Graphic jogging Robot trajectory Load program
Easy teaching
to actual robot

Others

Virtual TP
Simple Modeling
3D CAD data
2D-3D conversion Teach robot data
Parts modeling by same operation
IGES Library registration of actual robot
format

CAD Interface
Source: FANUC Robotics
Duty Estimation
Set payload (EOAT and Conditions (Ambient
Work-pieces weight, center temperature, cover option)
of gravity, inertia)

TP OVC, OH
Program Result

Simulation

Source: FANUC Robotics

Life Estimation
Actual cycle time
Working hours per day
Working days per year
Torque analysis
Simulation

Reducers life

TP
Program

Source: FANUC Robotics

Power Estimation

one cycle Power consumption Motion analysis

Simulation

TP
Program Annual power and electric toll

Source: FANUC Robotics

 Case Study Multi-Robot Workcell

Cycle Time
Robot 1 Machine Tending
Robot 2 Machine Tending
Robot 3 Packing
Robot Reach
Footprint Optimization
Sequence of Operation
Prevent Robot Interference
Case Study - Assembly

Cycle Time
Workcell Arrangement
Combined EOAT
Functions
Robot Reach
Footprint Optimization
Sequence of Operation
Case Study Packing Workcell

Simulation Allowed For

Combined Operations
Reduced From Two
Robots To One Robot
Robot Reach
Footprint Optimization
Sequence of Operation
Deep Containers
Required Attention To
Moment Loading
Custom Simulation Package For Spot Welding

Critical space

3 2 1 3 2 Robot Robot
3D CAD 1
model
1234

4 321

Robot #2
Robot #1
Servo gun posture Assign points to each Compute the
normal to surface robot group and sort critical space and
the order of assigned setup the interlock
points to minimize the signals
path distance

Source: FANUC Robotics

 Case Study Spot Welding

Robot Interference
Cycle Time
Workcell Footprint
Sequence of Operation

Source: Octopuz
 Case Study Spot / Arc Welding Workcell

Tooling Clearance
Robot Clearance
Cycle Time
Workcell Footprint
Sequence of Operation

Source: Octopuz
Custom Simulation Package For Arc Welding

Work angle Push angle

Welding line

Linear Circular
motion motion

Approach Retreat
point point Avoid Collisions

Source: FANUC Robotics

 Case Study Arc Welding

Coordinate Reach With

Positioner
Verify Ability To Reach
All Weld Points
Check Weld Position at
Each Seam
Cycle Time

Source: FANUC Robotics

 Case Study Arc Welding

Coordinate Reach With

Positioner
Verify Ability To Reach All
Weld Points
Check Weld Position at
Each Seam
Confirm Operator Safety
During Unload / Load
Cycle Time

Source: FANUC Robotics

Custom Simulation Package For Palletizing
1. Specify the dimensions of the
work and the palletizing
pattern

Conveyor3
Work Dimensions

Conveyor2
2. Specify the transportation relationship between
Conveyor1 each conveyor and each pallet
3. Specify the work required on each conveyor
Pallet-Station3

Pallet-Station2
4. Generate palletizing Teach Pendant programs
Pallet-Station1

Source: FANUC Robotics

Case Study - Palletizing

Multi-Function EOAT
Slipsheets
Bags
Equipment Location
Footprint Optimization
Sequence of Operation

Source: FANUC Robotics

Case Study - Palletizing

Multi-Function EOAT
Pallet
Pails
Cases (2 Orientations)
Equipment Location
Footprint Optimization
Sequence of Operation
Case Study High Speed Picking

1. Parallel flow
(Life is good at steady state.)

Source: FANUC Robotics

Case Study High Speed Picking

2. Infeed speed/density
(Slower & denser is better.)

Source: FANUC Robotics

Case Study High Speed Picking
3. Boundaries settings
(When theyre good, theyre
good. When theyre bad.)

Source: FANUC Robotics

Case Study High Speed Picking
4. Variable flow
(This is the real world.)

Source: FANUC Robotics

Case Study High Speed Picking
5. Conveyor Stop
(Control your destiny.)

Source: FANUC Robotics

Case Study High Speed Picking
6. De-coupling
(Do it if you can.)

Source: FANUC Robotics

Case Study High Speed Picking
7. Counter Flow
(Its not the silver bullet.)

Source: FANUC Robotics

Case Study High Speed Picking

Robot Position
Conveyor Height and
Position
Conveyor Speed
Number of Robots
Required to Maintain
Production Rate
Custom Simulation Package For Material Removal

Library

CAD Data

Definition of a workcell Placement of the devices models Selection of a chamfering line

Rotate Tooling to
avoid collision

Generate Program with Simulation

Specify Tool Rotation
Collision Avoidance

Source: FANUC Robotics

Case Study Material Removal

Process To Part
Cycle Time
CAD-To-Path
Orientation of Deburr
Spindle Relative To Part
Case Study Material Removal
Part to Process
Cycle Time
Need For Two Robots
Minimize Footprint
Prevent Robot
Interference
Benefits of Robot Simulation Software
Quickly Test Numerous Options With Simulation Software.
Qualify Applications Faster And More Accurately Than With
Manual Methods.
Validate Robot Applications Without Acquiring Costly
Equipment.
Validate Robot Applications Without Time Consuming Workcell
Set Up.
Perform What If Analysis of Installed Robotic Systems With No
Down Time.
Use of Simulation When Things Go Wrong

Manual Load/Unload Spot Welder Operation

Spot Welding - Simulation
 Spot Welding - Installation

Simulated 20kg Robot

Selected 50kg Robot

Typical Features of Process Line Simulation Software

Beyond The VRC (Virtual Robot Controller)

Replicate and test complex mechanical systems.
Control the simulation using an actual PLC logic simulation.
Optimize part-handling operations.
Analyze component usage to easily find bottlenecks before the cell is
ever built.
Visualize the shop floor process from start to finish.
Setup I/O communication between components.

Source: Octopuz
 Process Line Simulation
Robotic Case Packing
Case Recirculation
Tote Box Conveying
Pallet Feeding
Gantry Palletizer

Source: Octopuz
Benefits of Process Line Simulation Software

Reduced Cost of Change With Early Detection of Product and

Process Design Issues.
Reduced Number of Physical Prototypes Through Virtual
Validation.
Optimized Cycle Times Through Simulation.
Virtual Validation of Both Mechanical and Electrical (PLC and
Robotics) System Components and Processes

Source: plm.automation.siemens.com
The Future of Robot Simulation
More Specialized Application Tools
Spot Welding
Arc Welding
Palletizing
Picking
Painting
Material Removal
Improved CAD-to-Path
Recent Enhancements
Modeling of Robot Dress-Out
Safety
Ergonomic Considerations
Robot Simulation Summary
Powerful
More Features Being Developed
Improved Ease of Use
Remote Program Editing
Has Moved Beyond Path and Cycle Time
Payload / Moment Check
Interference
Duty Cycle
Robot Life Cycle Estimate
Broader Perspective: Look At Entire Process Line
Cost Effective Tool
Test The System With The Model!
Robot Simulation Doesnt Crash The Robot!
Contact Information

Charles C. Gales, P.E.

Manager, Automation Sales

Weldon Solutions
425 East Berlin Road
York, PA 17608
USA

Telephone: 717-846-4000
Email: cgales@weldonsolutions.com

www.weldonsolutions.com