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-piece’s 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

Reducer’s 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 they’re good, they’re
good. When they’re 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
(It’s 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 device’s 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 – Doesn’t 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