leveraging cnc-controlled robots in manufacturing · coordination of multiple robots w/ machine...
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Leveraging CNC-controlled Robots
in Manufacturing Presented by Roger Hart
Manufacturing in America │ March 14-15, 2018
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Before we start… A Penny for Your Thoughts
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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
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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
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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
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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.
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CNC Controlled Robots
Leveraging the Best of Both
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SINUMERIK Run MyRobot —
Portfolio
SINUMERIK provides a complete range of robot integration possibilities,
from intelligent interfaces to fully integrated robot kinematics.
Functional scope
SINUMERIK
Run MyRobot /EasyConnect
Communication via PLC I/O interface
Operation and programming of the
robot via robot control
828D 840D sl
SINUMERIK
Run MyRobot /Machining
Continuous path control with
SINUMERIK
Connection at the motion control level
All CNC programming methods are employed
Digital twin with NX-CAM and VNCK
828D 840D sl
CNC
CAD
CAM
SINUMERIK
Run MyRobot /Direct Control
SINUMERIK
Run MyRobot /Direct Control
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
828D 840D sl 828D 840D sl
CNC
CAD
CAM
SINUMERIK
Run MyRobot /Direct Control
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
828D 840D sl
CNC
CAD
CAM
SINUMERIK
Run MyRobot /Handling
SINUMERIK
Run MyRobot /Handling
Robot commands via PLC
Complete operation and programming of the
robot via SINUMERIK Operate
828D 840D sl 828D 840D sl
PLC
SINUMERIK
Run MyRobot /Handling
Robot commands via PLC
Complete operation and programming of the
robot via SINUMERIK Operate
828D 840D sl
PLC
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Fu
ncti
on
al sco
pe
Depth of integration
Full functional scope of
Run MyRobot /Machining
+ • System-integrated robot mechanical
system
• Robot control using SINAMICS
drives
• Additional robot compensation
• No additional robot controller
Run MyRobot /Direct Control
Full integration of the robot
into the production process
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
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 /EasyConnect
Communication via
PLC-I/O interface
Robot operated with robot
controller
Connect handling robot
quickly and easily
SINUMERIK Run MyRobot portfolio
- from simple connection to full integration of the robot
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Run MyRobot /Direct Control —
Overview
Simple configuration with direct connection of the robot.
This solution ensures high precision and better dynamics.
Robot Data
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SINUMERIK Run MyRobot /Direct Control
- integrated process chain for CNC machining using robots
3. Engineering
Create MyConfig
TIA Portal
Sizer
• NX CAM Robotics
• VNCK
2. Robot
simulation
NX CAD
NX CAE
Teamcenter
Virtual.Lab
1 1. Machine
design
4. Offline programming
and operational integration
Run MyRobot /Easy Connect
Run MyRobot /Handling
Run MyRobot /Machining
Run MyRobot /Direct Control
Mindsphere
SINUMERIK Integrate
OPC UA
MTConect
5. Data transparency
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Feature / function Benefits
• Single point of operation • Efficient operation via the CNC
• CNC programming acc. to
• standard DIN 66025/ ISO 6983
• ProgramGUIDE
• Efficient programming of the
machining robot with G-Code
• No robot-specific knowledge
necessary
• 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
• Robot diagnostics via SINUMERIK
Operate
• Fault remedying by the machine
operator
• Operator does not have to be
retrained
• Minimum downtimes Time
Higher productivity of the machine tool
- by involving the robot in the machining process
Time Nu
mb
er
of
fin
ish
ed
part
s
Higher machine productivity of the overall plant:
with hybrid machining with MyRobot /Direct Control
Robot
MT
Handlin
g
Handlin
g
Machin
ing
Machin
ing
Machin
ing
Workpiece measurement with measuring cycles
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Precise continuous-path control in the machining process
- full CNC functionality directly on the robot
Feature / function Benefits
• Dynamic compression of G0/G1/G2/G3
blocks in polynomial
• Shortest block change times
• High machining precision
• Significantly better look ahead than robot
control
• Optimum calculation of velocity
profiles
• 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
Polynomial format
Reference
contour
Tolerance
band
CNC Look Ahead
N1 N12
Feedrate
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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
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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 • Even greater precision of the path
control
• No robot controller needed
MT and robot implemented on one and
the same controller
• 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
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From virtual to real production
• 840D sl Post processor incl. Cycles
• Adaptable to individual application with Post Configurator
CAD CAM Programming
CAM Simulation
CAM Post processor Production
NX SINUMERIK
• Integrated Solution for product development • Complex drilling and multi-axis operations • Simulation of the operation on the basis of the real kinematics
NX CAM and SINUMERIK — the perfect process chain for machining with robots
Path Accuracy ? Absolut Accuracy?
Highest path Accuracy
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Error classification for 6-axis robots
Static Error
Dynamic Error
Geometric Error (e.g. link length, tools, objects in workspace) Elasticities (base, run-out, gears) Temperature (quasi static)
Following error Gear Cyclic Errors Axis Dynamic Limits
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Error classification for 6-axis robots
Static Error
Dynamic Error
Geometric Error (e.g. link length, tools, objects in workspace) Elasticities (base, run-out, gears) Temperature (quasi static)
Following error Gear Cyclic Errors Axis Dynamic Limits
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Accurate system through robot calibration (UCI + Isios)
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
Absolute accuracy: At the TCP, for arbitrary manual orientations, for approaching positions
from arbitrary directions, in the whole machining area
Customer requirements Calibration Compensation
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
Compensation
data set
Compensation
data set
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References
Siemens AG Technology Center, Chemnitz
Robot type: KUKA KR300 R2500 Quantec with milling spindle
Max. arm length: 2.75 m, distance TCP – flange: 283 mm
Application: Robot-based milling
Independent tracker check measurement :
Average fault (AF): 0.91 0.19 mm
(before the milling spindle, milling cutter tip calibrated)
Standard deviation (SD): 0.49 0.10 mm
Maximum error (MaxErr): 2.41 0.63 mm
Robot on the linear axis
Arm length: 3.4 m
Distance meas. point - flange: 190 mm
Independent tracker check measurement
Average fault (AF): 1.61 0.22 mm
Standard deviation (SD): 0.74 0.10 mm
Maximum error (MaxErr): 4.19 0.52 mm
Robot on the linear axis
Max. arm length: 2.6 m
DistanceTCP - flange: 470 mm
Independent tracker check measurement
Average fault (AF): 4.91 0.22 mm
Standard deviation (SD): 2.22 0.09 mm
Maximum error (MaxErr): 10.79 0.54 mm
Customer A Customer B
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Error classification for 6-axis robots
Static Error
Dynamic Error
Geometric Error (e.g. link length, tools, objects in workspace) Elasticities (base, run-out, gears) Temperature (quasi static)
Following error Gear Cyclic Errors Axis Dynamic Limits
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The basic idea: a universal 3D Multi-body Model
Real Robot 840D sl – SINAMICS/SIMOTICS Compile cycle ROCO
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
Source: MABI Robotics
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 .. .
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Conformity of model and real robot
External device for measurement
X-direction
Y-direction
Z-direction
3 N/µm
0.3 N/µm
0.6 N/µm
0.04 N/µm
1.1 N/µm
0.08 N/µm
X
Z
Y
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Adaptive Torque feed forward
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
Pose 1 Adaptive T.-FFW Fixed T.-FFW: Jax = 0,01 kgm2 Fixed T.-FFW: Jax = 0,018 kgm2 Fixed T.-FFW: Jax = 0,025 kgm2
Pose 2 Adaptive T.-FFW Fixed T.-FFW: Jax = 0,01 kgm2 Fixed T.-FFW: Jax = 0,018 kgm2 Fixed T.-FFW: Jax = 0,025 kgm2
Pose 3 Adaptive T.-FFW Fixed T.-FFW: Jax = 0,01 kgm2 Fixed T.-FFW: Jax = 0,018 kgm2 Fixed T.-FFW: Jax = 0,025 kgm2
0 1 2 3 4 5 6 -0.02
-0.01
0
0.01
0.02
Po
sit
ion
RA
11-A
xis
[°
]
Time [s]
5° 3° 1°
RRR11.ST1
RU11.ST1
RM11.ST1
RR11.ST1
0 1 2 3 4 5 6 -0.02
-0.015
-0.01
-0.005
0
0.005
0.01
0.015
0.02
Po
sit
ion
RA
11
-Axis
[°
]
Time [s]
5° 3° 1°
RRR14.ST1
RU14.ST1
RM14.ST1
RR14.ST1
0 1 2 3 4 5 6 -0.02
-0.015
-0.01
-0.005
0
0.005
0.01
0.015
0.02
Po
sit
ion
RA
11-A
xis
[°
]
Time [s]
5° 3° 1°
RRR1A.ST1
RU1A.ST1
RM1A.ST1
RR1A.ST1
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Gear and Joint Cyclic Errors —
Measure
- Exemplary for axis 2 Functionality: Measure path deviation
(in multiple directions) for each axis
Determine periodic error function
Compensate for load dependent cogging effects of the gears based on the 3D multi-body model
Effect: Higher path accuracy
-0.1
-0.05
0
0.05
0.1
Devi
atio
n [
mm
]
Perp
en
dic
ula
r to
circula
r pla
ne
-140 -120 -100 -80 -60 -40 -20 -0.1
-0.05
0
0.05
0.1
Devi
atio
n[m
m]
in c
ircula
r pla
ne
Angle [°]
Setpoint path
Measured path
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Gear and Joint Cyclic Errors —
Calculate error function and compensate
- Exemplary for axis 2 Functionality: Measure path deviation
(in multiple directions) for each axis
Determine normed periodic error function Compensate for load dependent cogging effects
of the gears based on the 3D multi-body model Effect: Higher path accuracy
i
i
n
i
iAx
2
1
22 2sin
-20 -40 -60 -80 -100 -120 -140 -0.1
-0.08
-0.06
-0.04
-0.02
0
0.02
0.04
0.06
0.08
0.1
Angle [°]
Po
sit
ion
[m
m]
-140 -120 -100 -80 -60 -40 -20 -3000
-2000
-1000
0
1000
2000
3000
Angle [°]
To
rqu
e [
Nm
]
-0.1
-0.05
0
0.05
0.1
Devi
atio
n [
mm
]
Perp
en
dic
ula
r to
circula
r pla
ne
-140 -120 -100 -80 -60 -40 -20 -0.1
-0.05
0
0.05
0.1
Devi
atio
n [
mm
]
In c
ircula
r pla
ne
Angle [°]
-20 -40 -60 -80 -100 -120 -140 -0.1
-0.05
0
0.05
0.1
Angle [°]
Po
sit
ion
[m
m]
20 10 9 8 7 6 5 4 3 2 1,5 1 0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
Wave length [°]
|Po
sit
ion
[m
m]|
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Axis Dynamics —
Adaption of Acceleration
- Exemplary for Axis 1 - Torque in the drive train is limited - Motor inertia and stiffness of the drive train
are known - The max. acceleration can be computed
depending on the pose and hence depending on the total inertia of the axis
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 1st 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
0
2
4
6
8
10
12
14
16
18
20
0.00
0.20
0.40
0.60
0.80
1.00
1.20
0.01 0.02 0.03 0.04 0.05 0.06 0.07
Fre
qu
en
cy [
Hz]
Accele
rati
on
[re
v/s
2]
Sum inertia [kgm2]
Max. accel First eigenfrequency
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Axis Dynamics —
What is the jerk?
Jerk Limitation with Sinumerik
Path
veloci
ty
SOFT BRISK
Without jerk limitation »BRISK«
With Jerk limitation »SOFT«
Smooth Movements: 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 1st 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
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Axis Dynamics —
Adaption of Jerk
- Exemplary for Axis 1 - The jerk limitation is proportional to the
first Eigen frequency of the robot axis - It has been verified that the overshoot
remains under 0,005°during positioning
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 1st 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
0
1
2
3
4
5
6
7
8
9
10
0.00
0.20
0.40
0.60
0.80
1.00
1.20
0.01 0.02 0.03 0.04 0.05 0.06 0.07
Jerk
lim
it [
m/s
3]
Accele
rati
on
[re
v/s
2]
Inertia [kgm2]
Max. jerk for tol. 0,005° Max. accel Computed max. jerk
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Axis Dynamics —
Example
- Exemplary for Axis 1 - Positioning time (45°, F5000) when adapting
acceleration and jerk
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 1st 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
0
0.5
1
1.5
2
0.01 0.02 0.03 0.04 0.05 0.06 0.07
Po
s.
Tim
e [
s]
Inertia [kgm2]
Pos. Time with adaption Pos. Time without adaption
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Absolute path accuracy
- the controller makes the difference
Reference
contour
Tolerance
band
0,001 – 0,05mm 0,7 – 2mm
CNC-Algorithms
Direct Encoders
Calibration
0,2 – 0,7mm
Machine Tools Standard robot SINUMERIK
RMR /Direct Control
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Static + Dynamic Accuracy, what can it do?
Reference
contour
Tolerance
band
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Seminar Slides
After MiA, seminar slides will be available at:
http://www.usa.siemens.com/mia-seminars
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Questions?
Roger Hart
Head of R&D, DF MC Machine Tool Systems
Siemens Industry, Inc.
4170 Columbia Road
Lebanon, OH 45036
Phone: +1 513 218-1626
E-mail: roger.hart@siemens.com
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