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: 1Hephestos
Project Duration:
September 2012 to December 2015
Project Partners:
VTT (Oulu)MAG (Helsinki and Oulu)UiAFraunhofer IPK (Berlin)Easy‐Rob (Frankfurt)MEM (Berlin)G‐Robots, Vezprem HungaryComau, TorinoUPM, Madrid
Budget: 2,4 MEUR
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: 2Demonstrator Cell 1Hephestos
Location: MAG, Oulu, FinlandRobot: NH3‐220kg‐2.7mSpindle: Colombo ~10kWForce Sensor: ATI Omega160Laser Tracker: FARO Xi
Questions:
1) Can a standard industrial robot be used formachining of metals (aluminium,bronze,steel) or will the deflections of the arms be too large?
2) Can the robot’s toolpath be correctedthrough software to compensate for thedeflections of the arms?
Why use robots for machining?Bigger workspace, lower cost
4000km return trip. Trip has been made twice: June 2013 and June 2015.
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: 4Video From 2nd TripHephestos
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: 5Tests: Aluminium, bronze, steelHephestos
Tests at Oulu, Finland (25.‐28. June, 2013)Experimental Setup:• Robot: IRB6660‐1.9m• ATI 6‐DOF Force sensor• FARO Xi Laser Tracker• Tools: SECO Minimaster, 2‐ and 3‐flute• Materials: Alu, Bronze, Steel
Steel, cut depth: 0.2mm to 0.5mm
X
Y
Z
X
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Tool: 12mm, 2‐fluteSpindle Speed: 7400 RPMRobot speed 12.5mm/sCut Depth: 1. 5mmCut direction: PullCut width: 100%, 25%
MillingDirection
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Material: BronzeTool: 16mm, 3‐fluteSpindle Speed: 10000 RPMRobot speed 50mm/sCut Depth: 0.25mmCut width: 100% ,66%Cut direction: Push Milling
Direction
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Material: BronzeTool: 12mm, 2‐fluteSpindle Speed: 12900 RPMRobot speed 29mm/sCut direction: PushCut width: 100%, 25%Cut Depth: 0.25mm
Experimental Results: Bronze
MillingDirection
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Material: Steel S355Tool: 12mm, 2‐fluteSpindle Speed: 4100 RPMRobot speed 10mm/sCut Depth: 0.2mmCut direction: PullCut width: 100%, 50%Comments: chattering
meanx = 0.0443meany = ‐0.0121Mtheta = ‐1.5100Mrho = 0.7301
MillingDirection
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Experimental Results: SteelHephestos
Material: Steel S355Tool: 12mm, 2‐fluteSpindle Speed: 4100 RPMRobot speed 10mm/sCut Depth: 0.5mmCut direction: PushCut width: 100%, 66%
meanx = 0.0553meany = ‐0.0697Mtheta = ‐0.8995Mrho = 0.0890
MillingDirection
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Experimental Results: SteelHephestos
Material: Steel S355Tool: 16mm, 3‐fluteSpindle Speed: 4500 RPMRobot speed 22mm/sCut Depth: 0.2mmCut direction: PushCut width: 100%, 50%
MillingDirection
meanx = 0.0092meany = ‐0.0309Mtheta = ‐1.5576Mrho = 0.7014
Cycle bounds
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Hephestos Software Integration: Challenges
Software Integration inHephestos is a Challenge:
• Distributed Organisation• Different Operating Sys‐
tems (Win, Linux, Android)• Different development
platforms (Matlab, C/C++,Androi Apps, Win EXE)
• A flexible environment isneeded.
• EASY‐ROB is used as theintegration platform.
• The use of standalone DLLfiles and TCP/IP interfacesencouraged.
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Hephestos Integration Framework
http://uia.mechatronics.no
Dedicated server
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Hephestos Example from Hephestos ORL Server Interface
Speed test: 1000 x ORL Jacobians, on average 56ms (client in Norway) and 143ms (client in Germany)Speedup is possible, for example 1000 Jacobians in one request.
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Hephestos Hephestos Switchboard (EASY‐ROB)
The Switchboard GUI is designed to match the Conceptual Outline in Slide 2.
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Hephestos G‐Code Import (EASY‐ROB)
First version of G‐Code Importer ready (developed by EASY‐ROB).
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Hephestos User‐Frame / Reachability (UiA / EASY‐ROB / IPK)
Development of this functionalityusing ORL Server has started.
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Hephestos PDL2 Post‐Processor (COMAU/IPK/EASY‐ROB/UiA)
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Hephestos Simulation Run (EASY‐ROB)
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Hephestos Extended Elasticity Model + Jerk Limitation (COMAU)
Jerk Limitation:
1. Feed trajectories with C4G/C5G Open
2. Approximate the trajectory in PDL2a) Many LIN+CIRC movesb) Circular FLYc) Adaptive tuning of lookahead tables
Not yet decided if EEJM and Jerk Limitationwill be included in Hephestos demos.
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Hephestos Target Compensator (UiA)
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Hephestos Stiffness and process models
Milling:‐ Along the x‐axis : consider Y displacement
‐ Along the y‐axis : consider X displacement
‐ Diagonal (XY) : consider both XY displacements
X, Y, Z
Alternatives:Jacobian + Stiffness from ORL/EEJMProcess model from IPK
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Hephestos Target Compensator: Preliminary Results
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Hephestos New Experiment: 3mm depth (Alu) + Sand bag
meanx = 0.1526meany = 0.6020meanz = ‐1.1810 W/O Sand BagPEx = 0.1456PEy = ‐0.0110PEz = ‐1.2156
meanx = ‐0.1771meany = 0.5534meanz = ‐8.7226 Sand Bag PEx = ‐0.1386PEy = ‐0.0022PEz = ‐8.6199
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Y
Conclusions:Mean error about 0.6mmSand bag reduces error ~10%
Heavy spindle: Reduces chatter,but increases static error in Z.
Red=No material
Blue=Milling
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Hephestos Path Modification: Implementation (1)
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Hephestos Path Modification: Implemenation (2)
• Available requests to the web server• Joint limits• Forward kinematics• Inverse kinematics
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Hephestos Path Modification: Implementation (3)
• Set material direction• Determine pull/push• User input
• Get offset• Calculate forces• Calculate offset
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Hephestos Conclusions
• The overall planning and programming architecture presented.
• To avoid lock‐in effect (Review II), partner software developedas standalone modules, but integrated in EASY‐ROB.
• First demo cell in the process of being set up (MAG, Oulu).
• The partners are currently working on integration of modulestowards the real demonstrators.
• Hephestos is an example robotic project of software integrationinvolving partners in many countries.
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