Online And Offline Programming Of Robot

Online And Offline Programming Of Robot – Complex robot applications often go through three phases in their life cycle: planning, programming, and maintenance. It is common for problems to arise at the interfaces between individual phases. On the one hand, because different people are responsible for the respective period, and on the other hand, different tools are used. A programming solution that covers all three phases and bridges the gap between different areas of activity offers many benefits. Especially when users can easily switch between online and offline programming. We will explain why.

Offline programming refers to programming a robot in a simulation environment, while online programming allows programming or testing directly on a real robot. Robot automation projects typically consist of three steps that involve dedicated online or offline work: planning, programming, and optimization during maintenance. Each phase requires specific tools, individual expertise and good coordination, as different people (roles) are often responsible for the respective areas.

Online And Offline Programming Of Robot

Online And Offline Programming Of Robot

Initially, programming and testing cannot yet be done on a real robot. Therefore, the planner relies on simulation tools to define and verify the geometric design, tools, and program sequence of the robot cell. It performs reachability analysis and collision checks, optimizes the sequence of robot actions, determines the most efficient trajectories and defines safety zones.

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At the next stage, the programmer faces the correction of missing or incorrect assumptions, as well as the transformation of the result into a complex robot program – often found only in the abstract form of CAD data, images and process descriptions. A programmer must write a robot for a vendor to accurately implement a planned process, flexibly calculate robot motion, communicate with PLCs, controls, and image processing systems, or integrate complex sensors such as torque sensors. code. If different suppliers are used, this will inevitably lead to increased effort.

Once the application is up and running in production, the maintenance team is expected to rapidly debug and refine (‘online’) not just one, but several complex robot programs for various robot manufacturers. In addition, changes related to shift work should be documented in a controlled and understandable manner. A programmer must prepare a complex robot program in the form of documentation, comments, and input masks in the best possible way so that the process information represented by the robot code is preserved as well as possible.

We are well aware of the challenges associated with these three stages of development. That’s why we developed the Robot Programming Suite (RPS), a fully integrated approach that seamlessly integrates online and offline programming (Figure 1). Now it is enough to use one product for all stages of robot-based automation (Figure 2).

The beauty of the method is that it can be easily integrated into existing processes, as the software automatically generates robot code that runs on the robot manufacturer’s standard controller. This eliminates interface problems between different tools. In addition, functional packages can be combined. This allows flexible use of resources and increases the efficiency of cooperation between individual domains. For example, more realistic results are produced with the same effort during the planning phase, and the robot programmer can produce them later with much less effort. The risk of serious problems arising only during the programming or commissioning phase is greatly reduced. It’s also easy to develop standards that apply to all robots thanks to data compatibility and an individual application catalog.

Online Robot Programming

“The amazing feature of our concept is that it allows us to implement not only special partial solutions, but also complex robotic automation projects as a whole. And this is with robots from all popular manufacturers,” explains Dr.-Ing. Andreas Hermann (Figure 3), .

Take just 30 minutes and we’ll show you how to easily, quickly, intuitively and consistently program, analyze and optimize robotic applications using RPS and LAR.

An optional web demo is a great way to see if RPS and LAR fit your needs and how the tools can support you.

Online And Offline Programming Of Robot

“After the first reports and presentations, I realized: this is exactly what we need. The Robot Programming Package allows you to create universal robot programming at a high level of quality.”

Robot Programming Software

Due to the ease of switching between online and offline, the software provides, among others, other benefits that positively impact programming. For example, when cleaning components or inspecting edges, robots often have to follow complex trajectories. It is trivial to program these trajectories in a motion-oriented manner and compare them to the actual workpiece. A different approach to RPS applies here. With the CAD2Path tool, CAD models of workpieces can be exported to the offline world and then used directly to automatically generate motion paths. For real-world comparisons, the programmer then goes online, moves the robot arm to a set of characteristic points on the workpiece, and trains them. Positions obtained from the digital twin can be transferred to the real robot and vice versa (Figure 4). Thus, complex paths can be programmed in a very short time. Even transport movements where accuracy is not critical can often be easily determined off-line, and exact target locations can be adapted online if necessary.

The ability to easily switch between the two worlds means that different solutions can be quickly evaluated directly on the robot, as training, programming and testing are closely linked. This is a big advantage, especially for applications that require more frequent testing due to programming complexity. Examples are torque sensors or camera systems and sensor-based applications that require much more programming effort and expertise than simple motions. “Almost all programmers” can abstract technology and focus only on processes, Herman explains. This also makes RPS an ideal tool for rapid prototyping of sensor-based assembly tasks. Programming, retraining, code generation, and testing shorten development cycles, and different solution strategies can be efficiently evaluated.”

In addition, the use of electric grippers, image processing solutions or torque sensors is greatly simplified and the user remains flexible during the installation phase. Even for components that offer only basic functionality, the initial effort to integrate them is often cumbersome, as multiple protocols must be implemented and drivers must be created. Here, the programming kit provides support for a wide range of protocols that take away this integration effort.

Finally, the seamless combination of online and offline programming is also beneficial for maintenance, as RPS facilitates the exchange of programmers. “The goal of our current developments is to continuously expand the ‘detached’ mode, meaning that even without RPS, a maintenance engineer can make certain changes to the generated robot code using the robot manufacturer’s standard techniques, such as remote point relearning. ” For example, a maintenance technician can now select individual training points. can improve with minimal effort and then push updates back to the software. This is very important, because otherwise the documentation and reality will not match and there will be significant changes. is lost when introducing additional systems.

Offline Robot Programming Software Simulation For Proof Of Concept

You can also analyze robot data from real work with optional LAR (Learning and Analysis for Robots) software. This enables production cycles to be optimized for stability, accuracy and speed. LAR also allows you to compare different program versions against each other. This way, the changes remain transparent and can be reliably determined, for example, whether the “optimization” is really better than the current version of the program. In addition, the maintenance engineer takes advantage of PDF documents, including saved comments that the programmer can create at the click of a button.

The programming package isn’t just fun for newcomers. It also offers a variety of solutions for companies that already have a robot code library and want to continue using it. On the one hand, code from previous applications can be combined and reused for future projects. On the other hand, the opposite approach can also be considered, i.e. for complex sensor-based internal processes, for example, the code is generated using RPS and integrated into the robot’s programming environment.

In general, it has always been important to the pur team that roboticists are not dictating to users how to use the code, and that a step-by-step transition is possible. “The integrated approach of online and offline programming, together with available control algorithms and driver libraries, enables process-oriented work and avoids the loss of focus due to time-consuming detailed applications,” says Herman.

Online And Offline Programming Of Robot

MORE THAN A SIMPLE ROBOT PROGRAM: With RPS, you create cross-process standardization from planning and programming to maintenance.

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Program and simulate robot applications independent of manufacturers, reduce maintenance costs and reduce skilled labor shortages. !Some methods of programming robots are better than others, learn how ZF succeeds. Here we discuss the 5 most common programming methods and their pros and cons.

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