Industrial IT for robotic applications

Citation

(2002), "Industrial IT for robotic applications", Industrial Robot, Vol. 29 No. 1. https://doi.org/10.1108/ir.2002.04929aaf.007

Industrial IT for robotic applications

Keywords: Robotics, Programming

Off-line programming is just like having the robot on your PC!

Off-line programming is the best way to maximize return on investment for robot systems. ABB's simulation and off-line program flung software, RobotStudio, allows robot programming to be done on a PC in the office without shutting down production. It also enables robot programs to be prepared in advance, increasing overall productivity.

All those things you can do on-line with your robot, i.e. on the shop floor, can now be done off-line. Robot Studio is the first, easy-to-use software for simulation and true off-line programming of a robot system on a standard Windows PC. By using an exact replica of the real ABB robot controller, Robot Studio can generate precise robot programs. The virtual controller uses the same software that is used to control the robot, and it generates executable RAPID-programs. This use of a virtual controller concept makes ABB the only supplier offering true off-line program wang.

Through the use of this tool, customers enjoy less risk by being able to evaluate new robotics solutions before the systems are up and running, and/or before any investments are made. Even before the physical equipment is installed, new robotic systems can be configured resulting in shorter time-to-production. Plant flexibility is also improved as automation scenarios and production changeovers can be designed, optimized and verified off-line without interrupting production.

Maximizing ROI

Cost-efficient off-line programming is the best way to maximize return on investment (ROI) for a robot system. RobotStudio reduces the life-cycle cost of a robot system in that it reduces the risk during planning by allowing the system to be evaluated before it is built. It then speeds up the installation by making it possible to create and test the robot programs as well as tram personnel before the system is up and running. Finally, it improves system uptime by moving the task of adjusting robot programs from the shop floor to the office, thereby fleeing up formerly occupied and precious production capacity.

The robot programmer creates the robot programs on a PC and tests different alternatives in the digital “robot cell” in order to find an optimized solution. Later, when changing the programmed pan, it is much easier for engineers to reprogram and tune the ABB robots, reducing programming cost and time. These cost reductions come in the form of quicker start up, shorter changeover, and increased productivity when modular solutions can be re-used on a large-scale (Plate 9).

There are many features that make programming quicker when done off-line. Examples are touch ups, moving of robot targets and path mirroring (exploiting symmetry and only programming one section, “mirroring” it to cover the rest of the path) – all which make the work easier and faster.

Plate 9 To achieve true off-line programming, Robot Studio includes the source code from the ABB S4 robot controller. RobotStudio's virtual controller uses an exact replica of the real robot controller to simulate the robot

Manufacturing industry has a lot to gain from simulating robots off-line. For example, the risk of making costly mistakes is reduced because the software confirms that the robot can reach all the programmed positions. It also calculates the cycle time required. This means reduced prototype testing requirements, less downtime and more efficient production planning.

By visualizing solutions in 3D, the risk of collision is reduced to zero. This, in turn, increases overall safety; the programmer discovers his mistakes on the PC instead of on the shop floor. As RobotStudio imports CAD files, the software works with very exact data. The robot programmer will then be able to generate more accurate robot programs, which in turn will give still higher product quality (Plate 10).

VBA compliant

Robot Studio is an open system. It interfaces with Microsoft Office, making it possible to use these familiar applications to extend its functionality. Like Office, it includes Visual

Plate 10 RobotStudio enables simulation and off-line programming of robot systems. The software package has the largest installed base of any robot simulation product on the market

Basic for Applications (VBA), letting the user customize its functionality for his special needs. For example, it is easy to export data to Excel. Microsoft recently approved a full API (Application Programming Interface) version of RobotStudio for customized process applications. This way, operators and plant management are better armed to make timely decisions.

Extended functionality

Robot Studio is available in both German and English. The software features customized templates that enable support for special processes, like stud welding. For high-quality CAD-models, RobotStudio supports CATIA as well as other common CAD formats. It also includes an intelligent wizard, making it easy to create robot tools.

Largest installed base

A “lite” version of RobotStudio is included with every ABB robot so that all users get the opportunity to try out this new way of working. RobotStudio Lite forms the largest installed base of any robot simulation product on the market.

Robot Studio is now firmly established as a successful tool, enabling the automation industry to increase productivity and improve quality still further.

Acknowledgement

This mini feature is an edited version of the article first published in ABB Review 3/2001.

Contact: Ulrika Sailsten, ABB Robotics AB, SE-41250 Gothenburg, Sweden. Fax: +46 31 773 8540; E-mail: ulrika.sallsten@se.abb.com