Robots have historically been taught manually, i.e. using the robot’s ‘teach pendant’ to manually drive the robot’s TCP to the desired point along the part to be operated on, while visually verifying – as much as feasible – the achieved accuracy. This is obviously a time-consuming process, to be painstakingly repeated for each (relevant) point along the robot’s path in space; furthermore, this process clearly doesn’t provide a high level of positional accuracy.
Robot Simulation software, commercialized nowadays by various companies, offers the ability to model an entire robot-cell on computer prior to dealing with it on the actual plant floor: a desired robot model is chosen, the end-effector and the fixture can be modeled, the part can be imported from some other CAD software – all that allowing the final robot program (with all required speeds and including any other desired commands) to be entirely created upfront through Simulation.
The created robot program is – theoretically – ready to be executed on the actual robot: this process is referred to as Off-Line Programming (OLP). More specifically, ‘Downloading’ is the process of transferring robot programs created through Simulation software in a ‘nominal’ environment, to the ‘actual’ robot-cell on the plant floor; ‘Uploading’ consists of transferring robot programs created on the ‘actual’ robot-cell on the plant floor, to the ‘nominal’ robot-cell in the Simulation software.
In reality, the differences between the ‘nominal’ world in Simulation and the ‘actual’ environment on the plant floor prevent from directly executing on the robot controller a robot program created through Simulation: each robot unit is built with certain manufacturing tolerances; the end-effector and its TCP deviate from their design intent; the fixture holding the part is not located relative to the robot coordinate frame as desired; etc. As a result, the robot programs downloaded from Simulation will not follow the intended path on the plant floor. This doesn’t just affect the positioning of the robot’s TCP, but it can also cause collisions between the robot and other peripherals within the robot-cell.
A robot program generated through Off-Line Programming is accurate enough if the resulting positioning accuracy of the robot’s TCP is within the acceptable limits for the intended application. For example, Off-Line Programming resulting in good enough robot programs for a paint job might not be so for an engine component assembly application. To maximize the success of Off-Line Programming (minimum manual robot program touchup and collision avoidance), it is generally imperative to perform ‘Robot-Cell Calibration’, and to correct accordingly (i.e. ‘Filter’) the robot programs to be downloaded. Use the DynaCal™ system for that purpose (see “Absolute Accuracy Robot-Cell Calibration“).
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Temperature compensation in robotics refers to techniques used to counteract thermal-induced errors in industrial robots, ensuring consistent positioning accuracy despite temperature fluctuations. The ambient temperature changes and the robot self-heating can induce the thermal related errors in the robot. Dynalog’s AccuBeam and DynaFlex products provide the ability to compensate robot for thermal-induced errors.
Robot guidance is the accurate identification of the part location with respect to robot. This feature is required when the part is not located repeatedly in the same location with respect to the robot.
Robotic inspection system is used to measure parts to identify the part dimensions and features are within tolerance. It includes an off the shelf industrial robot with a 3D sensor mounted to the robot end-effector. Dynalog’s DynaFlex system provides the high Absolute Accuracy and Accuracy Over-time required of such systems.
The roPOD system recalibrates the Tool Center Point (TCP) X, Y, Z, and Orientation. In addition, it can also recalibrate the zero-position mastering of the robot.
Yes, the roPOD system has a feature called “QuickCheck” that based on a couple of measurements of the end-effector can identify any change in the Tool Center Point.
Yes, the DynaCal system can calibrate the DH parameters of the robot, and also of the DH parameters of external axes (if any).
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