Software update news about digital manufacturing tools and software
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1 s Software update news about digital manufacturing tools and software Chahe Bakmazjian Business Team Leader Hypertherm Robotic Software Laurent, Quebec, Canada Programming Robots Gets Faster, Easier solutions use CAD/CAM software to convert paths to robot programs, which is a multisoftware approach and ensuring error-free programming becomes a challenge. In most cases, manufacturers end up using only a very small portion of the available workspace of the robot as without adequate errorfree programming tools that is the only method to ensure limited success. Existing methods are too complex, time consuming and labor intensive to be practical in today s highmix, low-volume production environment. By using Robotmaster, manufacturers can better program robots more quickly and efficiently, using industry-proven CAD/CAM software technology. Robotmaster integrates into the CAD/CAM-based CNC programming environment, Robotmaster integrates into the CAD/CAM-based CNC programming environment, and programming the robot trajectory is done graphically to produce error-free, six-plus-axis robot toolpaths. Manufacturing Engineering: How difficult is it to program robots for machining parts? Chahe Bakmazjian: Current technology typically requires hours, or even several days of programming before a robot is ready to perform its task. The problem lies primarily in the ability to integrate the right technology into a robotic application. More specifically, the flexibility of these robots remains a hurdle for companies that are looking to capitalize on opportunities within the robotics industry. Since 2001, Robotmaster has taken a special interest in the challenge of using CAD/CAM software for programming industrial robots. Having identified that robots are going to play a large part in manufacturing, a new breed of software, such as Robotmaster, will enable manufacturing shops to remove several hurdles the implementation cost and knowledge required for interactive simulation and error-free robot programming. With the continued move towards high-mix, low-batch type manufacturing, where the emphasis is more towards mass customization than mass automation, industries are expected to support and enhance the use of robots in their operations. Towards this, Robotmaster continues to build intuitive and easy-to-use robot programming software that is suitable for customers who have little or no expertise in robotics. ME: Describe how a manufacturer can program robots for machining purposes. Bakmazjian: While robot manufacturers have developed stiffer and more precise robots optimized for machine tooling applications, industry adoption is still slowed down due to the lack of adequate programming tools. Many of the current and programming the robot trajectory is done graphically to produce error-free, six-plus-axis robot toolpaths. As a result, Robotmaster eliminates this barrier by delivering cost efficiency and flexibility of robots coupled with the ease of programming. Furthermore, users can effortlessly address and overcome programming challenges such as singularities, joint limits, collisions, and reach limits, thus helping clients save time and money. ME: What new capabilities were added with the latest Robotmaster version? Bakmazjian: Recently, Robotmaster released Version 6.2 of its off-line programming software, offering enhanced design and usability along with several new feature sets. The work flow has been redesigned and will be at a minimum three times and up to 10 times faster than previous versions. In addition to core technology enhancement, V6.2 has been 30 AdvancedManufacturing.org November 2015
2 Software update designed to further elevate programming productivity, adding a synchronization feature which will allow simulations to synchronize any CAD/ CAM path modifications. What s unique about this enhancement is the integration of optimization and simulation allowing users to rapidly check for collisions and errors visually prior to running a full simulation. Together, these capabilities result in solutions that help make various industrial manufacturing applications more intuitive and collaborative while delivering fast, error-free robot programs. Aside from providing faster calculations in real time, the current version has a quicker work flow which will be less iterative. ME: How does 3D simulation help prove-out robotic machining processes? Bakmazjian: Unlike the wide range of simulation software packages that claim to be off-line programming for robots while truly only offering very limited programming capability, New Robotmaster Version 6.2 adds new work flow and simulation programming advances. Robotmaster delivers easy programming of precise tool motion control and quick generation of long toolpath trajectories with minimal programmer intervention. Conventional off-line ro- Image courtesy Hypertherm Robotic Software COMPACT Footprint NCREASED Throughput Belmont s new SY-3040 Series CNC EDM Drill combines a compact footprint with the performance demanded by the Aerospace Industry. Optional features include a tilt rotary table, automatic electrode & guide changer, as well as break through detection. Contact us today to put it to work for you in your industry. Everything for EDM Michigan :: North Carolina :: Massachusetts :: California :: Illinois Headquarters :: Phone :: 32 AdvancedManufacturing.org November 2015
3 bot software programming solutions are based on either a very cumbersome or tedious point-to-point programming approach or post-processor solutions that offer very little flexibility and functionality. With other programming solutions, intervention is manual and requires point-by-point input. Thus Robotmaster has an interactive environment with optimization tools that solves all errors automatically. ME: What machining tolerances are robots capable of obtaining for milling? Bakmazjian: Typically, robots have been designed with high repeatability and accuracy was not a feature that was quantified by robot manufacturers. Additionally, the older method of teaching accuracy was deemed not important as a taught program played back with high repeatability to get a job done. With the increased need for integrating off-line programming, accurate playback of the programmed path has become much more significant. In recent years, robot manufacturers have been offering enhancements such as factory-calibrated robots, where the robot is mastered by measurement to ensure accurate positioning when using off-line programs; special tools that are being offered for precise setups [calibrating user frames and tool center points]; and some robot manufacturers are offering special hardware configurations that are inherently more accurate. These include dual encoders for more precise positioning of the robot s joints, and more rigid robots for cases where higher process forces are required. A standard robot may be able to have an accuracy of ±1 2 mm. With a calibrated robot and setup, it is possible to achieve mm across most of the robot s workspace. ME: What customers are best deploying the technology for machining? Solid 2-5 Axis Modeling Milling Bakmazjian: Robotmaster has helped many companies looking to adopt robots for various applications such as trimming and cutting, deburring, welding, surfacing [cladding, polishing, and spraying] and many more. We work across various industries including aerospace, military, medical, and Change your shop s view of complex jobs. If you re looking for powerful CAM software that makes complex jobs seem like a day at the beach, GibbsCAM is YOUR CAM software solution. High-Speed Powerfully Simple. Simply Powerful Multi-Task Swiss Tombstone Turning Mill/Turn Wire-EDM November 2015 AdvancedManufacturing.org 33
4 Software update transport. For the past few years, Robotmaster has been responding to the growing demand for the robotic manufacturing of composites. Aerospace, defense, automotive, and ship manufacturing are all witnessing a strong demand for the use of composites. Applications such as trimming, drilling and riveting, inspection, etc., are crucial for success. To highlight a case study, a machining and metalworking fabricator was looking to start a new project that involved making their cutting and welding operation as precise and efficient as their CNC machining shop. Both precision and quality were crucial to the shop and getting it right the first time with a minimum number of operations and handling was extremely important. That meant that speed, accuracy, and programming, as well as production, were factors which needed to be carefully taken into consideration. Since adopting Robotmaster, the shop has significantly increased programming capability threefold; drastically improved the quality of parts [enhanced precision and better control over cutting parameters]; rapidly reduced programming time from hours to 90 minutes; and increased profitability [75% of their cutting production previously was outsourced, now down to only 10%]. Perhaps the most significant result is that Robotmaster enabled them to go from a CAD model to automatically creating an optimal cutting and welding program in only five days. ME: How will development of your software be affected by the recent acquisition of Jabez Technologies by plasma and waterjet machining manufacturer Hypertherm? Bakmazjian: As a small stand-alone company, our growth and resources were limited, but by joining Hypertherm we can access extensive engineering resources and a global sales and distribution network. This allows us to enhance support for existing programming applications, and also develop solutions for industries and applications that do not currently have access to Robotmaster off-line programming software. 34 AdvancedManufacturing.org November 2015
5 More companies will soon be able to simplify complex robotic programming for 3D shapes, program different robots across multiple processes, and take advantage of Robotmaster CAD/ CAM software for easy cell setup and configuration. Partnerships Components developer ModuleWorks GmbH (Munich) announced Sept. 28 that it would showcase its collision-avoidance software running on a FANUC CNC at EMO 2015 in Milan. The demonstration is the result of ModuleWorks partnership with FANUC Corp. (Rochester Hills, MI, and Japan). ModuleWorks will show its real-time collision-avoidance software running on the FANUC controller. The company said ModuleWorks collision-avoidance simulations shown on a FANUC CNC controller. Image courtesy ModuleWorks GmbH its technology will be available to any machine tool builder using FANUC controls. Simulation and collision checking is available in all controlled modes, including Jog mode, and can also be used for a dry run to validate NC programs before machining. The simulation may be connected to FANUC s virtual control software, NC Guide, to allow offline simulation during the design or programming stage. New Releases Okuma America Corp. (Charlotte, NC) on Sept. 23 introduced its OSP Suite, an open-architecture CNC control system that combines intelligent technologies with software to improve cycle and lead times while simultaneously achieving optimum machine conditions. Built on the OSP-P300 control, it combines an easy-to-use operating interface with customizable layouts, apps, widgets, shortcuts and touchscreen technology to improve shop-floor productivity. Users can also customize it with software from Okuma s App Store. Software Update is edited by Senior Editor Patrick Waurzyniak; pwaurzyniak@sme.org. November 2015 AdvancedManufacturing.org 35
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