Leveraging CNC-controlled Robots in Manufacturing Presented by Roger Hart Manufacturing in America March 14-15, 2018

Transcription

1 Leveraging CNC-controlled Robots in Manufacturing Presented by Roger Hart Manufacturing in America March 14-15, 2018

2 Before we start A Penny for Your Thoughts At the end of the session, share your feedback via MiA App - and get a chance to win tickets to the Detroit Tigers baseball game!

3 Why Robots? Compared to Traditional Machines Lower cost Smaller footprint Easier installation Larger reach Access to more sides of work-piece Work simultaneously on a single part

4 Why CNCs? Compared to traditional Robot Controllers Manage more complex end effectors requiring motion and integrated automation. Maintain common programming with CNC machines Reduced control complexity Integration of additional Kinematics Coordination of multiple robots w/ machine tools

5 CNC Controlled Robots Leveraging the Best of Both Robot kinematics can be part of a larger kinematic chain supported by the CNC For example a robot riding on a 3 axis Cartesian system with a rotating workpiece. Include end-effector axes Entire kinematics chain solved by CNC Traditional CNC TCP and orientation programming

6 CNC Controlled Robots Leveraging the Best of Both A single CNC can coordinate and synchronize multiple machines For example a Lathe with a loader robot and de-burring robot controlled by a single CNC.

7 CNC Controlled Robots Leveraging the Best of Both

8 Functional scope SINUMERIK Run MyRobot Portfolio SINUMERIK Run MyRobot /EasyConnect 828D 840D sl Communication via PLC I/O interface Operation and programming of the robot via robot control 828D SINUMERIK Run MyRobot /Handling 840D sl Robot commands via PLC Complete operation and programming of the robot via SINUMERIK Operate SINUMERIK Run MyRobot /Machining 828D 840D sl Continuous path control with SINUMERIK Connection at the motion control level All CNC programming methods are employed Digital twin with NX-CAM and VNCK CAD CAM SINUMERIK Run MyRobot /Direct Control 828D 840D sl Continuous path control with SINUMERIK (Single Controller) Full integration of the robot kinematics All CNC programming methods are employed Digital twin with NX-CAM and VNCK CAD CAM PLC CNC CNC SINUMERIK provides a complete range of robot integration possibilities, from intelligent interfaces to fully integrated robot kinematics.

9 Functional scope SINUMERIK Run MyRobot portfolio - from simple connection to full integration of the robot Run MyRobot /Direct Control Run MyRobot /EasyConnect Communication via PLC-I/O interface Robot operated with robot controller Connect handling robot quickly and easily Run MyRobot /Handling Robot commands via a PLC Complete operation and programming of a robot via SINUMERIK Operate Diagnostics and remote maintenance via SINUMERIK Operate handling robot and MT in a uniform way Run MyRobot /Machining Continuous-path control with SINUMERIK Connection at the motion control level Application of all CNC programming methods Digital twin with NX-CAM and VNCK Diagnostics and remote maintenance via SINUMERIK Integrate machining robot into the production process Full functional scope of Run MyRobot /Machining + System-integrated robot mechanical system Robot control using SINAMICS drives Additional robot compensation No additional robot controller Full integration of the robot into the production process Depth of integration

10 Run MyRobot /Direct Control Overview Robot Data Simple configuration with direct connection of the robot. This solution ensures high precision and better dynamics.

11 SINUMERIK Run MyRobot /Direct Control - integrated process chain for CNC machining using robots 1 1. Machine design 2. Robot simulation 3. Engineering 4. Offline programming and operational integration 5. Data transparency NX CAD NX CAE Teamcenter Virtual.Lab NX CAM Robotics VNCK Create MyConfig TIA Portal Sizer Run MyRobot /Easy Connect Run MyRobot /Handling Run MyRobot /Machining Mindsphere SINUMERIK Integrate OPC UA Run MyRobot /Direct Control MTConect

12 Number of finished parts Machining Handling Machining Handling Machining Higher productivity of the machine tool - by involving the robot in the machining process Robot MT Feature / function Single point of operation Benefits Efficient operation via the CNC Time Higher machine productivity of the overall plant: CNC programming acc. to standard DIN 66025/ ISO 6983 ProgramGUIDE Efficient programming of the machining robot with G-Code No robot-specific knowledge necessary with hybrid machining with MyRobot /Direct Control Milling cycles: face milling, drilling, pockets, engraving, etc. Low programming effort easy to parameterize Alignment and measurement of workpieces using measuring cycles Reduced setup times Familiar CNC Look&Feel Workpiece measurement with measuring cycles Time Robot diagnostics via SINUMERIK Operate Fault remedying by the machine operator Operator does not have to be retrained Minimum downtimes

13 Precise continuous-path control in the machining process - full CNC functionality directly on the robot Feature / function Benefits Reference contour Tolerance band Polynomial format Dynamic compression of G0/G1/G2/G3 blocks in polynomial Shortest block change times High machining precision Feedrate Significantly better look ahead than robot control Optimum calculation of velocity profiles N1 N12 CNC Look Ahead Path planning, interpolation, and transformation with CNC Machining programs are run more precisely and faster Tool management Length/radius compensation Magazine management Unit quantity/tool life monitoring Replacement tools Highly product machining processes with simple and intuitive operation Tool wear is taken into account

14 Optimized process chain - for CNC machining using robots Feature / function Benefits CAD / CAM process chain*: Programming, simulation Collision detection Working area Digital twin G-code based simulation Optimized process chain- for CNC machining using robot kinematics Reduced development times with parallelization Parallelized commissioning with virtual commissioning ("hardware in the loop") Reduce commissioning times Connection to higher-level IT Mindsphere * OPC UA * MTConnect * Data transparency of integrated robot cells Support for the I4.0 communication standard * optional expansion

15 One control for all tasks - by fully integrating the robot into the CNC Feature / function Benefits Three different connection options: Standalone Hybrid Handling Flexibility Reduction in the machining time No robot know-how needed SINUMERIK single controller concept No robot controller needed MT and robot implemented on one and the same controller Even greater precision of the path control Costs for hardware reduced Save space Preconfigured SIZER project Simple to configure Automatic conversion of robot data into SINUMERIK data (Create MyConfig) Robot data are implemented directly in the SINUMERIK Simple commissioning Improved performance

16 From virtual to real production CAD CAM Programming CAM Simulation Integrated Solution for product development Complex drilling and multi-axis operations Simulation of the operation on the basis of the real kinematics NX CAM Post processor 840D sl Post processor incl. Cycles Adaptable to individual application with Post Configurator SINUMERIK Production Path Accuracy? Absolut Accuracy? Highest path Accuracy NX CAM and SINUMERIK the perfect process chain for machining with robots

17 Error classification for 6-axis robots Static Error Geometric Error (e.g. link length, tools, objects in workspace) Elasticities (base, run-out, gears) Temperature (quasi static) Dynamic Error Following error Gear Cyclic Errors Axis Dynamic Limits

18 Error classification for 6-axis robots Static Error Geometric Error (e.g. link length, tools, objects in workspace) Elasticities (base, run-out, gears) Temperature (quasi static) Dynamic Error Following error Gear Cyclic Errors Axis Dynamic Limits

19 Accurate system through robot calibration (UCI + Isios) Customer requirements Calibration Compensation 1) Statement on the absolute accuracy of a robot 2) Statement stating under which conditions this applies 3) Consideration of the specific system features 4) Ensuring accuracy along the entire life cycle of the system Automated creation of the customer-specific calibration travel on the basis of the CAD data Fast measurement of several hundreds of points using an in-line measuring system Calculation of the model parameters and creation of the offset data record Compensation data set Compensation Compensation data set Absolute accuracy: At the TCP, for arbitrary manual orientations, for approaching positions from arbitrary directions, in the whole machining area

20 References Siemens AG Technology Center, Chemnitz Customer A Customer B Robot type: Application: KUKA KR300 R2500 Quantec with milling spindle Max. arm length: 2.75 m, distance TCP flange: 283 mm Robot-based milling Independent tracker check measurement : Average fault (AF): mm (before the milling spindle, milling cutter tip calibrated) Standard deviation (SD): mm Maximum error (MaxErr): mm Robot on the linear axis Arm length: 3.4 m Distance meas. point - flange: 190 mm Independent tracker check measurement Average fault (AF): mm Standard deviation (SD): mm Maximum error (MaxErr): mm Robot on the linear axis Max. arm length: 2.6 m DistanceTCP - flange: 470 mm Independent tracker check measurement Average fault (AF): Standard deviation (SD): mm mm Maximum error (MaxErr): mm

21 Error classification for 6-axis robots Static Error Geometric Error (e.g. link length, tools, objects in workspace) Elasticities (base, run-out, gears) Temperature (quasi static) Dynamic Error Following error Gear Cyclic Errors Axis Dynamic Limits

22 The basic idea: a universal 3D Multi-body Model Real Robot 840D sl SINAMICS/SIMOTICS Compile cycle ROCO Source: MABI Robotics X Z Y 3D-multibody-simulation Contains entire drive train of all axes Simulation in Matlab-environment Any kind of machine/ robot can be modelled Input data for each axis: Joint specific data: Inertia Tensor, Mass, Center of gravity, Stiffness (Trans/Rot) Axis specific drive train: stiffness and inertia of motor and gears Maximum allowable torque Functionality: Adaptive torque feed forward Compensation of cyclic errors at joints Adaptive Dynamic Limits More...

23 Conformity of model and real robot 0.3 N/µm X-direction 3 N/µm 0.04 N/µm Y-direction 0.6 N/µm 0.08 N/µm Z-direction X Z Y 1.1 N/µm External device for measurement

24 Position RA11-Axis [ ] Position RA11-Axis [ ] Position RA11-Axis [ ] Adaptive Torque feed forward Pose Adaptive T.-FFW Fixed T.-FFW: J ax = 0,01 kgm 2 Fixed T.-FFW: J ax = 0,018 kgm 2 Fixed T.-FFW: J ax = 0,025 kgm 2 Pose 2 Adaptive T.-FFW Fixed T.-FFW: J ax = 0,01 kgm 2 Fixed T.-FFW: J ax = 0,018 kgm 2 Fixed T.-FFW: Jax = 0,025 kgm2 Pose RRR11.ST1 RU11.ST1 RM11.ST1 RR11.ST Time [s] Time [s] 0.02 RRR14.ST1 RU14.ST1 RM14.ST1 RR14.ST1 Functionality: Feedforward the adapted torque depending on the current pose /inertia of the robot axis Effect: Elimination of pose dependent path deviations by reducing the following error to a minimum Higher path accuracy independently of the programmed feed rate Adaptive T.-FFW Fixed T.-FFW: J ax = 0,01 kgm Fixed T.-FFW: J ax = 0,018 kgm 2 Fixed T.-FFW: Jax = 0,025 kgm2 RRR1A.ST1 RU1A.ST1 RM1A.ST1 RR1A.ST Time [s]

25 Deviation[mm] in circular plane Deviation [mm] Perpendicular to circular plane Gear and Joint Cyclic Errors Measure - Exemplary for axis 2 Functionality: Measured path 0.1 Measure path deviation Setpoint path (in multiple directions) for each axis Determine periodic error function 0.05 Compensate for load dependent cogging effects 0 of the gears based on the 3D multi-body model Angle [ ] Effect: Higher path accuracy

26 Position [mm] Position [mm] Deviation [mm] In circular plane Torque [Nm] Deviation [mm] Perpendicular to circular plane Position [mm] Gear and Joint Cyclic Errors Calculate error function and compensate Exemplary for axis 2 Functionality: Measure path deviation (in multiple directions) Angle [ ] for each axis Angle [ ] Angle [ ] Determine normed periodic error function Compensate for load dependent cogging effects of the gears based on the 3D multi-body model 0.1 Effect: 0.05 Higher path accuracy Angle [ ] x n 2 2 A i 2 sin 2 i i1 i ,5 1 Wave length [ ]

27 Acceleration [rev/s 2 ] Frequency [Hz] Axis Dynamics Adaption of Acceleration Max. accel First eigenfrequency Sum inertia [kgm 2 ] Functionality: Adapt - the Exemplary acceleration for of Axis an 1 axis depending on the - pose Torque in the drive train is limited - Motor inertia and stiffness of the drive train of the robot (up to factor 5 between worst and are known best - pose) The max. acceleration can be computed Adapt the depending jerk depending on the on pose the and 1 st hence Eigen depending frequency on the total inertia of the axis (up to factor 4 between worst and best pose) Effect: Optimized dynamics for each robot pose Higher productivity while keeping the same high path accuracy Faster positioning with PTP

28 Path velocity Axis Dynamics What is the jerk? Smooth Movements: Jerk Limitation with Sinumerik BRISK Without jerk limitation»brisk«soft With Jerk limitation»soft«acceleration without undesired excitation of the mechanics Functionality: Adapt the acceleration of an axis depending on the pose of the robot (up to factor 5 between worst and best pose) Adapt the jerk depending on the 1 st Eigen frequency (up to factor 4 between worst and best pose) Effect: Optimized dynamics for each robot pose Higher productivity while keeping the same high path accuracy Faster positioning with PTP

29 Acceleration [rev/s 2 ] Jerk limit [m/s 3 ] Axis Dynamics Adaption of Jerk Max. jerk for tol. 0,005 Max. accel Computed max. jerk Inertia [kgm 2 ] Functionality: Adapt - the Exemplary acceleration for of Axis an 1 axis depending on the - pose The jerk limitation is proportional to the first Eigen frequency of the robot axis of the robot (up to factor 5 between worst and - It has been verified that the overshoot best pose) remains under 0,005 during positioning Adapt the jerk depending on the 1 st Eigen frequency (up to factor 4 between worst and best pose) Effect: Optimized dynamics for each robot pose Higher productivity while keeping the same high path accuracy Faster positioning with PTP

30 Pos. Time [s] Axis Dynamics Example Pos. Time with adaption Pos. Time without adaption Inertia [kgm 2 ] Functionality: Adapt the acceleration of an axis depending on - Exemplary for Axis 1 the pose - Positioning time (45, F5000) when adapting of the acceleration robot (up and to factor jerk 5 between worst and best pose) Adapt the jerk depending on the 1 st Eigen frequency (up to factor 4 between worst and best pose) Effect: Optimized dynamics for each robot pose Higher productivity while keeping the same high path accuracy Faster positioning with PTP

31 Tolerance band Reference contour Absolute path accuracy - the controller makes the difference Machine Tools SINUMERIK RMR /Direct Control Standard robot 0,001 0,05mm 0,2 0,7mm 0,7 2mm CNC-Algorithms Direct Encoders Calibration

32 Reference contour Tolerance band Static + Dynamic Accuracy, what can it do?

33 How did we do? Share your thoughts to win! Got 1 minute? Rate this seminar via MiA App for a chance to win Detroit Tigers tickets:

34 Seminar Slides After MiA, seminar slides will be available at:

35 Questions? Roger Hart Head of R&D, DF MC Machine Tool Systems Siemens Industry, Inc Columbia Road Lebanon, OH Phone: