Robot Operation Simulation for Faster Machining Program Generation

The patent creates a digital twin (virtual model) of the robot system that mirrors the physical system. This digital twin can be programmed and simulated virtually, allowing developers to create and test programs without interfering with actual production. The virtual model captures all relevant geometric, kinematic, and dynamic properties, enabling parallel development and testing activities that significantly reduce programming and development time.

The patent enables preliminary programming and simulation in the virtual environment before deploying to the physical robot. All program logic, path planning, and parameter optimization can be completed in advance in the digital twin, allowing for thorough testing and validation without affecting production schedules. This preliminary action in the virtual model eliminates the need for time-consuming on-site programming adjustments.

The patent establishes a digital twin that automatically copies and synchronizes data between the virtual and physical systems. Geometric data, kinematic parameters, and process settings are replicated in the virtual model, ensuring consistency across all operations. This automated copying eliminates manual data transcription errors and maintains version control, as the virtual model always reflects the current state of the physical system.

The patent implements bidirectional data synchronization between the virtual model and physical system. Changes in the physical system automatically update the virtual model, and validated programs from the virtual model are transferred back to control the physical robot. This feedback loop ensures data consistency and allows for automatic detection and correction of discrepancies, reducing operator errors while maintaining data accuracy.

The patent performs simulation and optimization only on critical aspects of robot operations rather than the entire system. Key parameters such as path optimization, collision detection, and cycle time analysis are simulated in the digital twin, while routine operations use pre-validated programs. This partial simulation approach achieves significant productivity improvements without requiring excessive computational resources for every operational detail.

The patent conducts comprehensive simulation and optimization in advance in the virtual environment before actual production runs. All critical path optimizations, parameter tuning, and scenario testing are performed preliminarily in the digital twin, allowing the physical system to operate with pre-optimized programs that require minimal real-time computation. This shifts the computational burden to the planning phase rather than execution phase.

The patent transfers the optimization complexity to the virtual model rather than requiring complex hardware modifications. The digital twin contains all the computational algorithms and optimization logic, while the physical robot system remains relatively simple. This copying of complex functions to the virtual environment enables automated optimization without significantly increasing physical system complexity.

The patent creates a universal optimization platform in the virtual model that can handle multiple robot types, applications, and scenarios through a single system. The digital twin framework is designed to be application-agnostic, supporting various robot controllers, end effectors, and process parameters through standardized interfaces. This multi-functionality allows automated optimization across different production scenarios without requiring separate complex systems for each application.