Special Patterns - Introduction - Manufacture of large things - - PowerPoint PPT Presentation

Special Patterns - Introduction

• Manufacture of large “things”
• Technology Provider

Deny Tanuwidjaja (M.EngElectronics and Control Systems)

• 6 Years Robot programming
• 4 Years Control systems programming
• 5 Years Head of programming

David Tumino (B. Eng. Robotics & Mechatronics)

• 5 Years CNC field engineering
• 4 Years machine design / robotic system design
• 5 Years Operations Manager / Head of Engineering

Special Patterns

Started in 1973 Traditional Pattern Making Early adopter of first CNC machines 6 x CNC machines and the largest being a 5 axis Macro Craftsman. Work envelope Of X 3200 Y 2500 Z 1000

Special Patterns

Robot Fabrication Cell

• Main focus is combining Hot wire

cutting and milling on the same workpiece to increase productivity

• Flexible
• Constantly adapted to the current job.

• Established to focus on Robotic Milling and Fabrication
• Design and build bespoke robot system
• Known for out of the box thinking with machine design

The robotics division of Special Patterns

Over 70 Robots… Over 30 Spindles…

Cobots Overview

2 types of collaborative robots

• TYPE 1: Force sensing
• TYPE 2: Area monitoring
• Limited model range in market place
• Growth area, we can expect to see more new models or cobots over the next few years

How Can CAM apply to cobots?

• TYPE 1: Force sensing

Limited type of end effectors that are “Safe”

• Glue / sealant dispensing
• Drawing / Art
• 3d Printing
• Pick / Place grippers

Not Safe:

• Miling
• Hotwire cutting
• Anything with a sharp edge!

How Can CAM apply to cobots?

• TYPE 2: Area Monitoring

Less restrictions on end effectors

• Glue / sealant dispensing
• Drawing / Art
• 3d Printing
• Pick / Place grippers
• Milling
• Hot Wire Cutting

How Can CAM apply to Cobots?

• RISK ASSESMENT ALYWAYS APPLYS

Robot Offline Programming Introduction

There are 3 levels of offline programming available: Tier 1 – SprutCAM, Robotmaster, PowerMill Robot

• High end Robot CAM software

Tier 2 – Grasshopper / KUKA PRC,

• Open platform, university development tool

Tier 3 – KUKA Sim Pro, ABB Robot Studio

• Simulation and robot reach functionality

Robot Offline Programming

Tier 1 Tier 2 Tier 3

Built-in robot pathing to follow selected CAD model features (mainly surface and curves) In general can generate path for the following applications

• Milling
• Trimming
• Welding
• Spraying

Create robot programs by CAD functions in Grasshopper Open platform (user can create custom function) No built in pathing and

• ptimisation
• Used for checking

layout and visual simulation

• No pathing function,

user create points same as manual programming

SprutCAM highlights

Simple steps to create tool path

• 1. Select part feature by clicking the

curves that is going to be trimmed

SprutCAM

• 2. Parameter settings to
• ptimise pathing

SprutCAM

• 3. Software generates path

SprutCAM highlights

• 3. Simulate path and review collisions.
• 4. Fine tune angles to avoid collision and

make smooth transitions

https://youtu.be/ls3v14YhkSg

Robotic Trimming Video

SprutCAM highlights

• 5. Spraying and additive functions

also available

KUKA PRC / Grasshopper Highlights

Open source, high level programming targeted at the Creative Industry and Universities. Grasshopper language knowledge required for programming Example image for a relatively simple part trimming

KUKA PRC / Grasshopper Highlights

For a single part, need to adjust the CAD features (curves, surface and meshes) to create the desired path behaviour.

KUKA Sim Pro Highlights

Native software from KUKA Relatively simple to reach check and layout presentation.

KUKA Sim Pro Highlights

No pathing capabilities. To program path need to manually snap to position, adjust angles and compensate for tool diameter

Combining Technologies

• Robots are flexible but do have limits
• CAM software pushes the robots limits
• with CAM different

cutting techniques can be combined

• 3d printing also a reality
• Hybrid cutting

HYBRID Cutting – EPS Foam

• Combining Hot Wire Cutting with CNC

machining

• “Roughing” can now be done 80% faster
• Straight to finish pass

Hybrid Cutting Video

https://youtu.be/0_oVejBXe0c

Accuracy of Robotic Milling

• Robots are Repeatable but are not accurate
• Understanding this will help make your

robot programs more accurate!

Accuracy of Robotic Milling

• Robots are Repeatable but are not accurate
• Understanding this will help make your

robot programs more accurate!

ROBOTS

Why?

• Robot rigidity / stiffness
• Robot kinematics
• 6 motors combine to make a straight line

But there is constant improvement from the robot manufactures

• 2009 KR210kg 2.7m reach robot flexed 1.1mm with 70kg loading
• 2016 KR120kg 2.9m reach robot flexed 0.7mm with 70kg loading
• Why? Better material science and robot construction

Accuracy Test Equipment

KUKA KR120 R2900 Robot Absolute Accuracy spec. KUKA.CNC Controller

RESULTS

100% % of point t we were: +/- 0.32 97% of points ts were: +/- 0.25 Min value: e: -0.322 22 Max value: e: 0.229 29 Mean: -0.07

CAM to Real World Example - Video

• Customer tolerance ±0.5
• 3d complex shapes
• Probe verification of cut lines and drilled holes
• Programed tool paths were “shifted” to the correct

position

Carbon fibre Trim Video

https://youtu.be/lsZ93bwCmPg

Collisions and Singularities in CAM

• What is a Robot Singularity?
• Robots can achieve the same

TCP position with different joint positions

Live SprutCAM Demonstration:

Thank you!

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