Product category:
Robots and robotic systems
News Release from: Fanuc Robotics (UK) | Subject: Off line programming
Edited by the Manufacturingtalk Editorial
Team on 30 April 2002
Off line programming trims routing cell
costs
Two robotic routing cells which were engineered, programmed and built to a 'commissioning ready' state from CAD data alone, have recently been installed at an automotive components supplier.
Two robotic routing cells which were engineered, programmed and built to a 'commissioning ready' state from CAD data alone, have recently been installed at Intier Automotive Faced with ever shortening lead time demands from customers including Jaguar, Rover, Ford and BMW, Intier wanted to meet its customers needs of reducing the critical path for new models and facelifts
This article was originally published on Manufacturingtalk on 11 Mar 2003 at 8.00am (UK)
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Roger Larcombe, Intier's Engineering Projects Manager explained, "We invested in two robotic machining systems 12 months ago when we were awarded the New Range Rover instrument panel mouldings contract.
The robot system was a radical change to the expensive and inflexible traditional punching methods.
These first systems were programmed conventionally with the tool locations being taught in the 'real world' using a finished component as a guide.
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When we were recently awarded the contract for the door panels of Jaguar's new 'flagship' model, code name X350, we decided to continue with the robotic approach.
We also decided to investigate ways to reduce the programming and commissioning process." After a tendering process Intier placed a contract onto Fanuc Robotics to engineer two systems with a commissioning deadline coinciding with the availability of door panels.
The implication on Fanuc was that as the systems were to be engineered concurrently to the door panel tooling, they would need to be built to a final commissioning ready state, without seeing a component.
"We felt comfortable with Fanuc's technical support and, possibly more importantly, that they bought in to the risk of the project", continued Larcombe.
Working with industrial simulation specialists, B4 (Lichfield), Fanuc modeled the complete system using the IGRIP simulation package.
Each cell consisted of one Fanuc M-710i Robot, a multi axes positioner, fixtures and enclosure.
Additionally, the CAD data from the door panel was translated into IGRIP to generate models.
After defining the cell sequence and programme commands in IGRIP the profiles of the panel were recorded together with the robot arm positioning mode at specific points.
Simulation of the cell followed this stage and unlike conventional system build methods, the robot arm was driven around the cell, for the first time, in its virtual world.
Any unreachable locations and collision points identified at this time were safely corrected by altering the programme without hard ware cost involved.
Julian Cashman, Fanuc's project manager, explains, "As the robot programme was created to the many CAD drawings relating to components in the 'virtual cell', compensation for the cell in the 'real world' was necessary.
To enable this, B4 used its Krypton metrology system to measure the robot and its environment, finding the nominal car reference frames in the real world referenced to the real robot.
"As the simulated robot programmes were developed from the same reference system, all that was needed on the shop floor was to update the reference frames in the robot controller from the nominal to the measured frames.
This process successfully aligned the robot programmes from the perfect CAD world to the real installation on the shop floor." The first component to be made available to the system was machined using the off-line programme and, without any modifications or intervention, was well within tolerance.
"On the programming and commissioning process alone we have saved several weeks over conventional techniques.
But the real savings will come in when we have to accommodate a modification from the manufacturer.
Firstly we will have the flexibility of the robot which removes the need for new tooling and secondly we can commence programming the very moment we receive the CAD data," commented Larcombe. Request a free brochure from Fanuc Robotics (UK) ...
(This was Manufacturingtalk's Top Story on 29 April 2002).
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