Robot Offline Programming for Collision-Free Workpiece Detection
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Solution Overview
Problem
Existing methods for correcting teaching positions in welding programs using contact sensors face challenges in avoiding interference between robots and workpieces during movement paths, posing a risk of damage and inefficiency.
Innovation Solution
An offline programming apparatus that generates a workpiece position detection program by designating contact points and automatically adding detection starting points and interference avoidance points in a virtual space to prevent robot interference, allowing for safe and efficient detection of workpiece positions using a contact sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the robot moves among a plurality of detection starting points to detect contact points, then the detection completeness is improved, but the risk of interference between the robot and workpiece increases
Solution Approach 1:
The system performs preliminary simulation of robot movement paths in virtual space before actual detection operations. Detection starting points are pre-calculated and interference is pre-detected through path simulation, allowing the robot to execute safe detection operations without real-time trial and error.
Solution Approach 2:
A virtual space model acts as an intermediary between the physical robot and workpiece. The simulation unit creates a digital representation where movement paths can be tested without physical contact, serving as a mediator to identify and avoid interference before actual operations.
2Speed
If the robot follows a direct path from detection starting points to contact points, then the operation speed is improved, but the risk of collision with the workpiece increases
Solution Approach 1:
Movement paths are pre-simulated and validated before execution. The system calculates optimal paths in advance that balance speed and safety, identifying collision-free routes through virtual simulation rather than relying on slow, cautious real-time movement.
Solution Approach 2:
The physical robot system is copied into a virtual simulation environment. Movement paths are tested on this digital copy, allowing rapid validation of multiple path options without affecting the physical system, thereby identifying fast and safe routes efficiently.
3Adaptability or versatility
If manual programming of detection paths is used, then the flexibility in handling complex geometries is improved, but the programming time and complexity increase
Solution Approach 1:
The system performs automatic path calculation and interference detection without requiring manual programming. The simulation unit autonomously analyzes the workpiece geometry and calculates appropriate detection paths, making the system self-sufficient in handling complex geometries without human intervention.
Solution Approach 2:
The system automatically adjusts movement parameters such as speed, acceleration, and path coordinates based on simulated interference conditions. By dynamically changing these parameters in the simulation, the system optimizes detection paths for complex geometries without requiring manual parameter tuning.
Data Source
AI summary
An offline programming apparatus includes a first part which causes an operator to designate contact points at which a contact sensor arranged at a distal end of a robot contacts a workpiece on a 3D model of the workpiece, a second part which automatically adds detection starting points in operations of the robot which approaches each of the contact points in directions of movement along coordinate axes of a reference coordinate system with reference to which the operation of the robot to detect the position of the workpiece is performed, at positions where no interference occurs between the robot and the workpiece in a virtual space, and a third part which automatically adds an interference avoidance point in the virtual space in order to avoid the interference if the robot and workpiece interfere with each other on a movement path of the robot which moves between the detection starting points.