SWOT Analysis of COSIMIR Software

a white paper for

Rixan Associates, Inc.
by
John R. Wright, Jr., Ph.D., CSIT
Department of Industry & Technology
Millersville University of Pennsylvania

January 15, 2005

Introduction:
Rixan Associates and Millersville University partnered in 2004 to improve the development and design of
the automation lab and control systems curriculum at Millersville University. Through this partnership
Millersville University has gained a state-of-the-art industrial robotics facility that is essential to their
Control Systems Industrial Technology programs. Rixan Associates has gained access to the intellectual
community of Millersville University and the partnership grant’s project director has evaluated the
strengths and weaknesses of a new emulation/modeling software package called Cell Oriented Simulation
of Industrial Robots (COSIMIR) as prescribed in phase II of the grant’s objectives.

Figure 1. COSIMIR Industrial (COSIMIR Web Presentation, 2005)

This report is intended to fulfill Millersville University’s grant/research obligations (phase II) to Rixan
Associates by providing a complete SWOT (Strengths, Weaknesses, Opportunities, and Threats) analysis of
the provided COSIMIR Industrial Version Product.

Strengths:
COSIMIR is a very powerful robot emulation package produced by the University of Dortmund in
Germany and is currently being sold commercially in Europe by Mitsubishi. The software contains libraries
of robots, end-effectors, geometric shapes/primitives (for custom development of objects and
machines/devices), and mechanisms such as conveyors and part feeders. The software also gives the user
the ability to import objects into the workcell that have been developed with a CAD package (dxf files).

The modeling of robot-based workcells is accomplished through the manipulations of objects, sections and
hulls. An example of an object is a robot; a section is part of an object such as the base rotation axis of a
robot; and hulls are attributes assigned to sections that are responsible for the graphical representation of a
section. Several hulls (geometric shapes) might be utilized to develop a section of a robot. This type of
structure makes up the COSIMIR model hierarchy and it allows the user to have quite a bit of flexibility in
the modification of an existing library object or in the development a customized object.

Although the industrial version (subject of this analysis) is limited to the use of a single robot in the
workcell model, the professional version has expanded robot libraries to include: ABB, Adept, Fanuc,
Kuka, Manutec, Niko, Reis, Staubli, VW, and others in addition to the Mitsubishi line.
One very nice and useful characteristic of the software is the ability to manipulate the programmer’s view
of the cell during the development and even the testing of the cell. The software allows one to zoom in and
look through object sections to attain viewpoints that would not be possible in the real world (i.e. zooming
in to look at the position of the object placed inside a laser cleaner). It is like giving the programmers
selected “X-ray” vision.

Once a cell has been developed, the code and positions may be taught utilizing a very user-friendly
environment. The simulator option “Collision Detection” is also a very pragmatic and highly useful tool.
Although the simulation time takes longer to view when this option is selected, the software will identify to
the developer if an object (i.e. the robot) should accidentally hit another object such as a milling machine’s
doorway. The software simply shows this potentially serious crash/error by highlighting the objects that are
affected during the simulation. The user can then zoom in on the problem area and resolve the potential
problem. Once a successful run has been tested using the collision detection option, the option can be
turned off to increase the simulation speed and flow for presentation to management or a client.

Downloading the robot code and positions to the robot is done very easily via the Robot Controller
Interface (RCI) Explorer. RCI is the information-processing center of COSIROP (Cell Oriented Simulation
of Industrial Robot Programming), the programming software for Mitsubishi Industrial Robots. Any of the
Mitsubishi supported programs and position files may be downloaded/uploaded to the robot via the use of
the RCI Explorer. The robot may then be initiated via the software and tested after a successful download.

On-line (email) support from the Institute of Robotics Research was very responsive and helpful. In most
cases, a response was received to programming/modeling questions within 24 hours. Given the time change
that exists between the United States and Germany, the support has been exceptional.

Weaknesses:
The biggest weakness of the COSIMIR product is that it approximates the robot acceleration/movement
times. This impacts the accuracy of the workcell cycle times that are displayed/reported.

We do not have knowledge about the internal algorithms used by Mitsubishi, so there will
be always a gap between the cycle time in the simulation and the real cycle time. But we
are trying to get as close as possible (Heinze, 2005).

Limited tests, using a Mitsubishi 2AJ, conducted at Millersville University indicate that robotic movements
modeled in the software take approximately 5% more time than that of the actual robotic movement timed
with a stopwatch. These tests were limited to a single program that executed Melfa -Basic IV MOV and
MVS commands to eight randomly selected positions in space. When utilizing the Project Wizard tool in
the software, the same 2AJ robot does not perform as well. The time predicted by COSIMIR with this
method projects cycle times of the robot’s movements approximately 45% greater than actual.

I just checked the model generated by the wizard and it seems that its acceleration is not
that well parameterized. We will update the models generated by the wizard in the next
version (Heinze, 2005).

Until the wizard’s parameters are corrected, it would be better to avoid its use. Other Mitsubishi robot types
were not tested at Millersville University. It is suggested that they be tested side-by-side with the software
to ensure confidence of the COSIMIR projected cycle times.

Limitations of the industrial version of the software include the use of only a single robot and the absence
of a PLC simulator in the workcell. The robot must serve as the supervisory controller. These deficiencies
and the expansion of the software’s libraries are eliminated via the use of the professional version of
COSIMIR, but at a substantial cost increase. Although the end-effector options available from the libraries
in the industrial version appear to be quite diverse, it should be noted that the Rixan part #RD300117
Pneumatic gripper was not available.

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Manuals provided have improved since the 2004 training at Rixan Associates. Due to the flexibility of the
COSIMIR software (i.e. manipulation capability), it will require a substantial learning curve for most users
even though the manuals have been updated.

Opportunities:
Possible opportunities for the COSIMIR product include using it for inside sales and engineering, aiding
Rixan’s existing customers, and the potential use of it for the educational market (Harris, 2005).
Millersville University’s qualitative examination of the product indicates mixed recommendations
regarding these possible opportunities of the software.

Use of the COSIMIR modeling software as an engineering tool shows much promise. Although the
product’s modeling of the Mitsubishi robots is not 100% accurate (see weaknesses section above), the use
of such a tool could empower even an inexperienced engineer with the ability to obtain cycle times of an
entire workcell fairly quickly. Once an engineer or technologist has mastered the learning curve associated
with this product, he/she would be able to produce a model and obtain a fairly accurate cycle time that
could be utilized to aid management on a potential bid for an integration project. Even with years of
experience with robotic solutions, senior engineers will appreciate the ability to make “what if” scenarios in
the 3D world to optimize a solution prior to the actual prototyping phase. Rixan will still rely on its senior
engineers to develop and optimize its solutions, as the software will only model what it is programmed to
do. Creativity and experience enhances its use. COSIMIR is a tool that if coupled with the “right”
personnel, can be very advantageous to a system integrator.

The powerful tools of the COSIMIR® package help you throughout the planning,
programming and test phases. Reachability checks in the early planning stages help you
to select the most suitable robot systems for the task. You can move the robots and other
work cell components around in the simulation at will, making it easy to optimize the
layout of your system (COSIMIR, 2005).

Inside sales will benefit from the use of COSIMIR through the use of it as a presentation tool. It will
increase the communication of Rixan’s proposed solutions to their existing and potential customers. If it is
true that “a picture is worth a thousand words,” than a 3D virtual simulation will likely add value to
Rixan’s sales force. Currently, Rixan presents 2D drawings as part of their proposals. The addition of the
third dimension, depth, combined with animation could be quite a powerful sales tool.

The product may have some limited potential to Rixan’s existing customers. It is probably best suited to
large companies that have system integrator talent and to third party system integrators that utilize and
purchase Mitsubishi robots from Rixan. For most of Rixan’s industrial customers, the software is likely to
be too expensive and complicated to use without a substantial amount of product support. The educational
market may also have some potential, but it is recommended that Rixan should concentrate on the use of
the product internally (engineering and sales) prior to examining these two other possible opportunities.
Once Rixan’s personnel are well versed with the use of the software, they will be better equipped to help
assess the resources needed to support the COSIMIR product line.

Threats:
The largest threat to Rixan is that the COSIMIR full product line is currently available for the United States
educational and industrial market through FESTO Corporation. Per a phone conversation with a FESTO
representative (January 14, 2005), FESTO is offering the following COSIMIR Products (See Table 1):

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 Table 1. FESTO Corporation COSIMIR Pricing
COSIMIR Product Single Copy Six Copy License
Professional Version 4.1 $11,198.00 N/A
Industrial Version 4.1 $4,160.00 $13,920.00
Factory Version N/A N/A
PLC $637.50* N/A
Educational 4.1 $490.00 N/A
*Networking capability is additional

This pricing schedule appears to be below the pricing that Rixa n had hoped to price the product line. It is
recommended that Rixan further investigate the product’s pricing, specifically the pricing available to
Rixan, prior to the purchase of any of the COSIMIR product line for any of its internal or external
customers.

FESTO currently does not provide any training classes on COSIMIR. When asked whether they support the
product, a FESTO representative stated that they do have trained staff not only here in the United States,
but through their German partner company as well.

Training and product support may constitute another threat to Rixan should they decide to market the
product to its external industrial and educational customers. The amount of product telephone support could
(in the estimation of this researcher) be substantial, due to the significant learning curve that must be
undertaken by those who would utilize the product.

Conclusions:
COSIMIR is a very powerful 3D industrial robot and workcell simulation software package. Use of the
COSIMIR modeling software as an engineering tool shows much promise. Inside sales will also likely
benefit from the use of COSIMIR via a presentation tool. Once Rixan’s engineering and sales personnel are
versed with the use of the software, they will be better equipped to judge the resources needed to support
the COSIMIR product line should Rixan ever decide to market the product externally. Rixan should
investigate their competition and resources prior to the decision to move from internal (engineering and
sales) use to external marketing of the product. It is the also recommended that Rixan investigate a better
price from the Institute of Robotics Research for the Professional Version of COSIMIR and then purchase
it for their internal engineering and sales functions.

Sources Cited:
COSIMIR (2005). COSIMIR® Industrial – Integrated Simulation and Programming Software. Accessed
online (January, 2005). http://www.axicont.com/Cosimir.htm
COSIMIR Web Presentation (2005). COSIMIR Industrial. Accessed online (January, 2005).
http://www.cosimir.com/English/COSIMIRManufacturing/COSIMIRIndustrial.htm
Heinze, F. (2005). More COSIMIR Questions [Email Response]. The Institute for Robotics Research.
January, 2005.
Harris, S. (2005). COSIMIR Software. Rixan Associates, Inc. [Phone Conversation]. January, 2005.