Coating Robot Path Optimization for Redundant Axis Configuration
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Solution Overview
Problem
Current offline programming methods for multi-axis painting robots are complex, especially for redundant robots, requiring extensive manual input and are not reproducible, leading to inconsistent coating quality due to programmer skill variations, and necessitate frequent adjustments with changes in robot position.
Innovation Solution
An optimization method that calculates an optimized trajectory for a coating robot by determining path-point-related and sequence-related quality values for various robot configurations, selecting the best configurations to avoid collisions, minimize movement, and ensure efficient axis travel, using a calculation unit within a coating system that includes a rotary atomizer, robot controller, and programming device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If offline programming methods are used for multi-axis painting robots, then the robot path can be programmed in advance, but the programming process becomes very complex and requires extensive manual input
Solution Approach 1:
The system automatically determines robot configurations and optimizes trajectories without requiring manual programming input. The calculation unit autonomously processes path points and generates optimized robot paths, eliminating the need for complex manual offline programming while reducing programming time and complexity.
2Adaptability or versatility
If manual programming is used for robot paths, then the path can be customized, but the quality of programming depends on the experience and skill of the programmer, leading to non-reproducible results
Solution Approach 1:
The patent replaces manual programmer expertise with an automated calculation unit that systematically determines optimal robot configurations and trajectories. This substitution eliminates variability introduced by different programmers' skills and experiences, ensuring consistent and reproducible programming results while maintaining path customization capabilities through automated optimization algorithms.
3Adaptability or versatility
If the position of the painting robot is changed, then the robot can adapt to different work positions, but the programmed robot path must be adjusted frequently
Solution Approach 1:
The system dynamically adapts the robot path based on the actual robot position. The calculation unit continuously determines optimal configurations and trajectories based on current path points and robot states, allowing the system to automatically adjust to position changes without requiring manual reprogramming, thus maintaining flexibility while reducing adjustment time.
4Adaptability or versatility
If redundant robot configurations are used, then the robot has more flexibility in positioning, but determining the optimal configuration becomes more difficult
Solution Approach 1:
The calculation unit systematically evaluates multiple robot configurations by analyzing path point parameters and determining quality values for each configuration. It optimizes the selection of robot configurations by changing and comparing parameters such as axis positions and orientations, automatically identifying the optimal configuration from multiple possibilities based on predefined criteria, thus managing complexity while maintaining flexibility.
Data Source
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AI summary
The invention relates to an optimisation method for calculating an optimised movement path of a coating robot (1), comprising the following steps: defining consecutive path points of the movement path using path point data, wherein the path point data defines the spatial position and orientation of the application device (7) at each path point; calculating possible robot configurations for the individual path points of the movement path, wherein each robot configuration includes all axial positions of all robot axes (A1-A7) and at least some of the path points can be reached optionally via multiple different robot configurations; calculating a path point-related and preferable also sequence-related quality value individually for the different possible robot configurations of the individual path points, such that each robot configuration is assigned a respective quality value; and selecting one of the possible robot configurations for the individual path points according to the quality value of the different possible robot configurations. The invention also comprises a corresponding coating system.