Journal of Intelligent Manufacturing (2023) 34:2765–2781

https://doi.org/10.1007/s10845-022-01928-x

Digital Twin and web services for robotic deburring in intelligent

manufacturing
Liliana Stan1 · Adrian Florin Nicolescu1 · Cristina Pupăză1 · Gabriel Jiga2

Received: 29 September 2020 / Accepted: 28 February 2022 / Published online: 26 May 2022
© The Author(s), under exclusive licence to Springer Science+Business Media, LLC, part of Springer Nature 2022

Abstract
The development of modern manufacturing requires key solutions to enhance the intelligence of manufacturing such as digi-
talization, real-time monitoring, or simulation techniques. For smart robotic manufacturing, the modern approach regarding
robot programming and process planning aims for both high efficiency and energy-awareness. During the design and manu-
facturing stages, optimization becomes crucial and can be fulfilled by means of appropriate digital manufacturing tools. This
paper presents the development of a Digital Twin for a robotic deburring workcell along with the process planning and robot
programming. Considering a large size workpiece, a new robot programming solution was implemented, based on image
processing to safely re-machine only areas where burrs could not be completely removed in the main deburring routine.
The work also covers the development of a new web platform to remotely monitor the robotic workcell, to trigger alerts
for unexpected events and to allow the control to authorized personnel enabled by the employment of robot web services
following an architectural RESTful style which establishes a communication link to the robot virtual controller. The aim of
this research is to integrate the Digital Twin with the innovative proposals of Industry 4.0, offering a project-based model of
smart robotic manufacturing and experience concepts such as Cyber-Physical System, digitalization, data acquisition, contin-
uous monitoring, and intelligent solutions in a novel approach. Furthermore, the work covers energy consumption strategies
for energy-aware robotic manufacturing. Finally, the results of an energy-efficient motion planning along with signal-based
scheduling optimization of the robotic deburring cell are discussed.

Keywords Digital twin · Industrial robot · Web services · Robotic deburring

I NTRODUCTION Alongside the evolution to Industry 4.0, various studies

claimed that an important part in successfully implement-
In the Industry 4.0 era, factories are moving towards the smart ing the Industry 4.0 strategy is to adapt higher education
manufacturing paradigm by implementing key solutions for to the requirements of this vision, especially in engineer-
system modelling, simulation, information acquisition, data ing. (Mourtzis et al., 2018). Several studies were published
analysis, intelligent decision making and more, in order to in the last decade, focused on the new qualification require-
enhance production capabilities for better quality, higher effi- ments of engineers while others presented road maps to adapt
ciency and lower energy consumption. Industrial Internet of manufacturing education to the requirements of Industry 4.0
Things (IIoT) has been increasingly studied in recent years by specifying mandatory changes of the curriculum or by
bringing technical challenges that are today closer to be over- introducing new learning conceptual frameworks and meth-
come. ods. Early in 2013, an educational Program was presented
by (Baladrón et al., 2013), where engineers completed their
traditional knowledge with more practical, industry-oriented
B Cristina Pupăză contents, proved that this approach fosters better knowledge,
[email protected] skills and qualifications.
The paper presents the main elements of the authors’
1 Robots and Manufacturing Systems Department, Politehnica training setup (i.e., a new Digital Twin (DT), robot Off-
University of Bucharest, Bucharest, Romania
line programming (OLP), a new deburring algorithm, energy
2 Strength of Materials Department, Politehnica University of consumption monitoring, web platform) that offers research
Bucharest, Bucharest, Romania

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engineers the necessary robotic programming knowledge by studying the use of a tool with passive radial compliance
to practice and develop intelligent solutions for robotic in a robotic process of deburring an injection molded plastic
machining and path planning along with energy consump- workpiece.
tion analysis. The training environment offers the means to The aims of this work are to offer a detailed study on
tackle the innovative challenges of Industry 4.0 and get ready the development of a DT model of a physical robotic FMC
for the smart manufacturing demands by getting a hands- and of a web-based platform along with an in-depth robotic
on experience on concepts such as cyber-physical systems OLP technique, and to propose a deburring solution based
(CPS), virtualization, process planning, and interoperability on an algorithm that generates the machining toolpath of
concerning workcell components. Furthermore, the new web partially removed burrs after video inspection. The paper
platform enables research engineers to get accustomed with continues with a general study of the energy consumption
specific robotic cloud technologies, manufacturing process of the industrial robot, describes the benefits after imple-
monitoring and intelligent decision-making. menting the deburring solution and presents the monitoring
The employed software tools are currently used by engi- capabilities of the web platform on the robotic FMC.
neers in industry, making the knowledge acquired a valuable In the second section of the paper, relevant concepts for
skill for devoted researchers. For the development of the DT, modern robotic manufacturing, robotic deburring and tool-
ABB RobotStudio provided the necessary environment to path planning, robot energy consumption, remote monitoring
virtualize the robotic workcell, to generate a collision-free and related work are discussed. In the third section, the new
tool path and to program the robot via OLP techniques by DT model and the new toolpath algorithm are presented,
taking into consideration sensor data and virtual models of along with discussions on robot programming and energy
physical components included in the physical workcell, thus consumption. Another contribution of the work is presented
simulating the process, analyzing the motion results, and in the fourth section and consists in a novel web platform
evaluating the robot energy consumption. which is used for remote monitoring and control of the
Additionally, ABB RobotStudio was employed to define a robotic deburring cell. The results are summarized, and future
virtual controller which runs the robot considering the work- planned activities are discussed in the last section.
cell sensors layout that was mapped to be remotely accessible
via the web platform. The platform uses web services to com-
municate with the virtual robot controller and offers the most
suitable solutions for data acquisition, data storage, process Related work
monitoring, safety, and control. Data can be collected contin-
uously from the physical workcell, and relevant information Modern robotic manufacturing systems
can be stored in a database. With well-defined manufac-
turing Key Performance Indicators (KPIs), the production Cyber-Physical Systems (CPS), Digital Twins (DT), Cloud
volume can be monitored, and the cell reliability and effi- Computing (CC), Internet of Things (IoT), Big Data Analy-
ciency can be evaluated. Data visualization tools have been sis (BDA), sensor technologies and machine learning (ML)
implemented to the web platform for real-time monitoring techniques are all enabling concepts for intelligent manu-
and condition-based alerts have been set up to trigger warn- facturing and taking into consideration recent developments,
ings for unexpected events via a messaging system. For the new trends in research and design have emerged for smart
development of a messaging bot, ActiveChat’s Visual Builder factories.
was employed to set up the alerts along with appropriate The DT of a manufacturing system is described as a
instructions for authorized personnel offering the means to sensor-enabled digital model of a physical asset that sim-
react accordingly in a timely fashion. ulates the object in a live setting (Grieves, 2015) and over
The main contribution of the holistic approach is bringing the past decade more definitions have arisen from industrial-
together Industry 4.0 specific concepts (i.e., virtualization, filed perspectives (Stark et al., 2017), (Zhuang et al., 2018),
OLP, image acquisition and processing, energy-aware robot together with their use in various industries, such as manufac-
programming, and process monitoring) to work seamlessly, turing (Tao & Zhang, 2017), (Zhang et al., 2017), (J. Wang
collecting data, and presenting it in interactive visualization et al., 2019), (Tong et al., 2019) aerospace (Tuegel et al.,
modules enabled by robotic web services. 2011), (Uzun et al., 2019), automotive (Vachalek et al., 2017),
Robotic path planning strategies for machining have been (Tharma et al., 2018) and even healthcare (Liu et al., 2019),
well covered in the literature, although focusing mainly on (Rivera et al., 2019). In the most recent studies, (Lim et al.,
machining processes such as deflashing of metal casts or 2019), (Barricelli et al., 2019), the authors emphasize both the
finishing of stir-welded corner joints and on the employment major role of DTs in a wide range of applications, including
of tools with active or hybrid control systems, specific for manufacturing control, system maintenance, robotics, and
quality precision machining work. This research fills a gap associated financial advantages.

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Cyber–physical interaction and integration is an impor- tool path with tolerance specifications of the workpiece (Ivan
tant prerequisite for smart manufacturing. CPS are known et al., 2015). Intelligent solutions to overcome these problems
to be multidimensional and complex systems that integrate arose, such as the robot tool compliance, workpiece point
the cyber world and the dynamic physical world. While DTs cloud matching, force feedback or vision guided trajectory
are digital copies of physical entities that can simulate and planning. Liao et al. developed a double compliant tool head
reflect their behavior through modeling and simulation anal- that controls the deburring force according to the variation
ysis, make predictions and control their future states through of the geometry in order to maintain a constant contact stress
feedback, CPS consider sensors and actuators as the main between the tool and the part (Liao et al., 2008). Wang et al.
modules. Both CPS and DTs pave the way for smart manu- proposed an intelligent compliance control solution using
facturing by forming a closed loop between the cyber/digital fuzzy logic (X. Wang et al., 2006) and recently Berselli et al.
and physical worlds based on state sensing, real-time anal- proposed a virtual prototype of a radial-compliant spindle to
ysis, information feedback, scientific decision-making, and optimize the deburring efficiency (Berselli et al., 2019).
precise execution (Tao et al., 2019). Toolpath planning solutions for robotic machining have
Several papers also focused on the robustness and intel- emerged to address the need for faster robot programming.
ligence of CPS and DTs, and stated unique requirements Kuss et al. presented an iterative algorithm that compares
(Tomiyama & Moyen, 2018) for their security (Humayed and matches the point clouds derived from the workpiece
et al., 2017), (Wu et al., 2017), resilience as a response to CAD model with a sensor point cloud obtained from a 3D
the processes need for scalability, efficiency and reliability measurement of the part (Kuss et al., 2016) and Abele et al.
to generate trustworthy data (Xu & Duan, 2019). presented a tool path speed optimization solution for debur-
For CNC machining processes, the Twin Control follows ring cross holes of complex parts (Abele et al., 2016). A
the CPS concept and aims to improve the performance and hand-eye, vision-assisted robotic solution for finishing stir-
productivity of machine tools at each life-cycle stage. An welded parts was presented in (Gurdal et al., 2019), in which
increasing interest for machine tools virtualization is visible the robot is equipped with a line structured laser sensor and
in the raising number of published works for DTs for CNC a pneumatic spindle with an adjustable deflection unit. The
machining operations (Armendia et al., 2019) and tool life authors presented a scan-and-machine approach consisting of
prediction (Luo et al., 2020). scanning and locating the workpiece in the robot coordinate
The virtualization concepts were also recently discussed system, automatic path programming and process parameter
for robotic manufacturing, although mostly focused on planning. Villagrossi et al. proposed a human mimicking con-
robotic assembly applications, involving collaborative robots trol strategy to remove burrs of hard material workpieces on
(Bilberg & Malik, 2019) or reconfigurable robotic workcells the basis of force feedback by removing thin layers of mate-
for small-batch production (Priggemeyer et al., 2018). Erdős rial each time (Villagrossi et al., 2018). Caesarendra et al.
et al. also presented an approach to transform already existing discussed the implementation of machine learning and cloud
workcells to parametric digital twins and tackled the chal- computing to improve deburring processes in aerospace man-
lenges of robotic finishing, such as grinding and polishing ufacturing (Caesarendra et al., 2019).
of cast aluminum parts. They demonstrated that the DT is Process simulation for tool path planning and generation
able to realize accurate tool path generation for the physical can increase milling productivity and part accuracy. Leftover
workcell (Erdős et al., 2020). A methodology for advanced burrs may occur during milling due to the peculiarity of the
physic-based modeling aiming to enable the DT of an indus- tool with radial compliance. Compliance is the ability of a
trial robot arm in predictive maintenance applications was tool to maintain contact and cutting force with the workpiece.
proposed in (Aivaliotis et al., 2019). It can be achieved through a variety of techniques that include
The purpose of this paper is to fill a gap in the literature for both active and passive force control systems.
virtualization techniques in robotic machining by presenting Active control systems require a data link to the robot
the DT of a robotic workcell for deburring plastic parts of controller to provide information and therefore are closed
large size. loop systems. Active force control tools deliver real-time
prompts to the robot to change its program trajectory as
Robotic deburring defined by a controlled correction routine. This can adjust
the path speed and the cutting forces, but active systems are
Robotic systems are known to be cost-effective solutions that typically more expensive than passive devices, however they
have the potential to fully automate the deburring processes offer more accuracy and repeatability. Passive force control
as a result of their high flexibility when moving along the systems do not measure any cutting forces, but simply adapt
edges of complex shaped parts. The drawback of this solu- to the part shape and apply a constant force. They are best
tion is that the stiffness of the mechanical structure of the suited for applications that have relatively consistent burrs
robot is low and problems arise to tune the accuracy of the

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or flash but have poor part-to-part tolerances. These systems EC is influenced by the operating parameters and constrained
greatly reduce gouging of the part by the cutter. by the workcell layout, productivity requirements and envi-
Radial compliance allows the movement from a center ronmental operating conditions.
position through 360 degrees along a radius of compliance In 2014, Paryanto et al. published a study on the EC of a
with a constant contact force in milling machining. Because robot arm in an assembly system. Later on, they proposed a
the cutting action is radial, they are also well suited for remov- modular model of a robot to analyze its power consumption
ing parting lines and flash from cast parts. For a more in-depth and dynamic behavior and demonstrated that the power con-
read about radial compliance tools, the authors recommend sumption can be predicted (Paryanto et al., 2014), (Paryanto
Berselli et al.’s paper on a virtual prototype of a pneumatic et al., 2015). Studies on minimizing the EC by optimizing
compliant spindle (Berselli et al., 2016) and Ivan et al.’s study the robot trajectories proved to be efficient as well (Hansen
of robotic low force milling operations using radial compliant et al., 2012), (Pellicciari et al., 2013). In their work, Bukata
end effectors (A. M. Ivan et al., 2019). et al. presented an approach to optimize the EC of robotic
A vision-guided robotic system (Leo Princely & Selvaraj, cells as a whole. More recently they proposed a new algo-
2014) was conceived for the deburring of simple 2D work- rithm designed to minimize the EC by changing the robot
pieces to avoid OPL procedures and recently, Rahul et al. speed, taking into consideration the robot positions as well
proposed another approach to identify burrs for 2D work- as the power-saving modes (Bukata et al., 2017), (Bukata
pieces using image processing and to generate trajectories et al., 2019). Uhlmann et al. conducted a study on EC of
(Rahul et al., 2019). However, both approaches generate industrial robots for machining processes and their experi-
the toolpath required to deburr the complete profile of the mental tests also showed that the robot movement speed has
workpiece and do not presume that due to the tool’s radial a major impact on the EC along with the cooling systems
compliance and burr thickness, some burrs could be only par- (Uhlmann et al., 2016).
tially removed. Using laser measurement systems to scan the Nevertheless, the literature shows a lack of studies focused
workpiece, to detect its position in the robot workspace, to on energy consumption monitored in robotic deburring pro-
generate approximate points and a sequence of frames that cesses. The presented paper aims to contribute to the research
describe the desired poses of the tool frame are also covered in literature for energy efficient usage of industrial robots
the literature for robotic machining processes such as deflash- employed in deburring processes as a result of path planning
ing of metal casts, finishing of stir-welded corner joints or optimization.
edge deburring of aero engine components (Jayaweera &
Webb, 2010). Such solutions use active or hybrid control Remote monitoring and control
systems, or other offline/online error compensation strate-
gies (Schneider et al., 2016). These approaches for toolpath Equipment performance and condition monitoring has
planning (which are also more costly) are not well suited for always been an essential part of the information systems
light deburring/deflashing where part tolerances are poor and used in industry to improve effectiveness and to minimize
radial compliance tools are used, as it is our case. unplanned downtime. The widespread deployment of various
The present work aims to address the robotic deburring sensors has made smart manufacturing possible. Nowadays
literature by focusing on tools with passive force con- data from various manufacturing objects, such as energy con-
trol, specifically tools with passive radial compliance and sumption, temperature or vibration can be assessed in real
by proposing a deburring algorithm that reduces the robot time. Smart monitoring provides graphical visualization of
energy consumption by optimizing the number of passes in the collected data and alerts when abnormality occurs.
the deburring routine only in areas with partially removed Monitoring of the manufacturing systems can be classi-
burrs caused by the tool’s passive radial compliance limita- fied into two main groups: monitoring the status of resources
tion. (related to machinery and environment monitoring, such as
machine workload, downtime, performance, etc.) or monitor-
Robot energy consumption ing the status of jobs (related to data of each task, sequence,
estimated production time, etc.).
Reducing the energy consumption (EC) of the robot is an Monitoring the manufacturing system does not directly
important step to improve the manufacturing system’s effi- control the physical system but it tracks it. Detailed status
ciency. Several studies have been conducted focusing on the on every physical system is supported by key performance
hardware aspect by considering strategies such as a lighter indicators (KPIs) such as schedule attainment, availability,
design of components or by using energy storing and recov- quality rate and overall equipment effectiveness. Studies on
ery devices. Another approach focuses on the software aspect Continuous and Discrete control operations have emphasized
to enhance the motion planning via trajectory planning or the importance of monitoring tools and techniques (Ramis
operation scheduling. In the optimization stage, the robot’s Ferrer et al., 2018).

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In a traditional robot cell, the service modules are inte-

grated with the control system and physical components
locally. A web-based robot cell aims to control the physi-
cal devices remotely over the network. Recent studies for
cloud manufacturing environments, cloud robotics and con-
trol systems as services have addressed the advantages and
challenges of having a remote control-access to a manu-
facturing system. The aspect of security has also been a
research topic for Industry 4.0 conceptual frameworks and
other works have shown how cyber-physical attacks (Goll-
mann et al., 2015) can be identified and counter-measured for
CPS (Munteanu et al., 2018) and specifically for Industrial
Robots (Quarta et al., 2017). Fig. 1 The Digital Twin of a robotic deburring workcell
In summary, the work presented in this paper explores
intelligent solutions for modern robotic machining and pro-
vides additional insights for readers to transform the robotic Virtual robot controller and offline programming
manufacturing DT towards a CPS architecture interlinked
with IoT where the manufacturing system’s capabilities can The robot toolpath was created to deburr the workpiece by
be extended and reconfigured. The paper tackles the chal- defining reachable targets choosing the most appropriate
lenge of using a tool with passive radial compliance in a robot configurations for the inverse kinematics solver to reach
robotic deburring process by employing a new algorithm all the target points. The robot movements were programmed
to compensate for the tool’s deflecting limitation by gen- to change the tools, and to pick up or place the workpieces
erating the deburring toolpath in areas where chips have from the gravitational aligning table to the fixture system and
been only partially removed. The presented DT offers a from the fixture system to the outfeed conveyor. Appropri-
good understanding on the impact the robot work cycles ate speeds together with the movement type, whether linear,
have on the energy consumption and provides the means for circular, or joint movements, have been defined for all the
energy-efficient robotic deburring though offline simulation moving instructions. Since workcell components are present
and OLP. The web platform uses robot web services to com- in the robot’s reachable space, the robot program was also
municate with the robot controller (virtual or real) to collect checked against collisions.
and present data focused on the robot energy consumption Four different tool center points (TCP) were set for: • the
and cell productivity (parts finished over time). robot’s tool mounting point, • the automatic changing system
QC-41’s master plate, • the deburring tool and • the vacuum
gripper. These TCPs are illustrated in Fig. 2. When the robot
The Digital Twin of a robotic deburring reaches a programmed target, it aligns the TCP’s orientation
workcell with the target’s orientation.
In addition to robot motion instructions, events have been
Modern CAD tools were employed for the modelling of the defined based on I/O signals which were created as com-
workcell components in accordance with their physical lay- munication channels between the controller and the external
out. Efficiency and reliability were the main requirements for equipment, for instance to start the outfeed conveyor once a
the DT representation. The proposed virtual model, which is workpiece was positioned by the robot as programmed, or
illustrated in Fig. 1, offers complete control on the manufac- to switch on or off the vacuum when the vacuum gripper is
turing process with regards to the design, planning, testing, used.
collision avoidance, fault detection, monitoring and process After validating all robot motions, the robot program
optimization. was uploaded in the virtual controller, which now stores
The manufacturing cell comprises a 6 DoF articulated arm each target position and orientation, robot configurations and
robot, ABB IRB 4600-40/2.55, equipped with a pneumatic sequences of moving instructions. The robot deburring tool-
end-effector with radial compliance, ATI Flexdeburr RC300, path and the sequences of robot movements are illustrated in
that deburrs an injection molded plastic workpiece. The use Fig. 3 (1), respectively Fig. 3 (2 and 3).
of an automatic system, ATI QC-41, allows the change of the The reliability of the entire system and the robot interac-
deburring tool with a vacuum end-effector for manipulating tion with the system is ensured by the programming based on
the workpiece. signals provided by the sensors. The workcell sensors layout
has been mapped to both the virtual controller and further on
in the web platform confirming that sensors information is

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Fig. 2 Tool Center Points: 1 - robot tool mounting point. 2 - QC-41 master plate mounting point. 3 - deburring ATI RC300 tool. 4 - vacuum gripper
point

Fig. 3 Robot deburring tool path (1), operations sequence (2) and the robot program loaded and shown on the robot flex pendant (3)

in sync. In addition, the reliability of the robot can also be anymore by the S2 sensor, the C-in conveyor starts, and the
verified by tracking the energy consumption. In cases when waiting workpiece wp enters the cell and slides in the right
the DT is scheduled based on events, not all actions can be position on the aligning table.
confirmed and therefore the reliability may not be assured. When picking up the workpiece from the sliding table,
The efficiency is determined based on the operating times the S7 proximity sensor positioned on the vacuum gripper
and the energy consumption. Any energy or operating time confirms that the workpiece to be grasped is already located
increases are visible in the web platform monitoring panel. in the right position before starting the vacuum. To ensure
Efficiency is not statistically calculated for a standard cycle that the workpiece has been successfully gripped, the robot
but depends on the actual execution time of each part. enters a condition loop where it is programmed to execute a
The robotic manufacturing cell OLP and simulation are short retraction movement: if the workpiece is still detected
further detailed in the next chapter. by the S7 proximity sensor, the robot will continue its move-
ment and exits the conditioning loop, but if the workpiece
is no longer detected, the robot will come back again to the
Robotic manufacturing cell offline programming workpiece and retry the picking up operation until it exits the
conditioning loop. Because the workpiece is laying in a cell
The robotic deburring cell structure is illustrated in Fig. 4,
where plastic debris is present this conditioning loop ensures
together with the sensors layout. The working cycle has three
that the working cycle is not interrupted by an unsuccessful
main stages. In the 1st Stage, the plastic workpiece (wp) is
gripping of the workpiece during the pick-up process.
brought by the in-feeder conveyor (C-in) and stopped near the
In the 2nd Stage, the workpiece is brought by the robot to
S1 sensor, waiting for a signal from the S2 sensor to confirm
the vacuum fixturing system (VFS), where another proximity
that the workpiece can safely advance on the gravitational
sensor (S4) confirms that the part is in range before activat-
aligning table (AT) which assures that each workpiece (Awp)
ing the fixturing system’s vacuum and deactivating the robot
will have the same position and orientation before it is picked-
gripper’s vacuum. The S3 proximity sensor confirms that the
up by the robot effector. A Cognex Integrated Vision System
robot has correctly placed the vacuum gripper in its fixture
(IVS) double-checks the workpiece position previously to
frame (VeS) and another sensor (S6) confirms that the debur-
the pick-up by the ABB robot, which is equipped with the
ring tool (Dt) is properly placed in the tool storage device.
Schmalz vacuum gripper (Ve). After the Awp workpiece is
picked up from the aligning table and therefore, not detected

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Fig. 4 Robotic deburring cell structure and sensors layout

The robot deburrs the plastic workpiece while a conveyor (C- the part (Dwp) is placed on the conveyor, it is detected by the
burrs) collects all the chips from the deburring process and S5 sensor which will stop the vacuum generator to detach the
evacuates them from the cell. When the deburring process part and then will start the conveyor with a certain delay, to
is completed, the robot places the deburring tool back in the allow a safely retract for the robot. The work cycle restarts,
tool storage system (TSS). The part is then video inspected and the robot will execute the operation of picking up the part
by the robot with a camera located inside the master flange from the sliding table when the S2 proximity sensor confirms
of the ATC system that follows the tool path. If burrs are that a workpiece is in the proper position.
still detected, a programming routine is activated to remove The conceptual CAD design comprises additional exten-
the remaining material from appropriate areas otherwise the sions, such as a gravitational aligning table or a storage device
robot picks up the vacuum gripper. for the deburring tool. Moreover, workcell components have
An algorithm was developed that generates the new tool- been designed in an effort to ensure that the DT closely
path required to remove remaining burrs captured by the emulates the physical workcell such as the Schmalz vacuum
visual inspection, limited only in the appropriate area where supply center (VSC) and the cell safety enclosure (SE). The
remaining burrs are present. This approach ensures that only workflow was analyzed together with the OLP and testing,
the strictly required time is spent to remove the remaining providing working cycle’s optimization. All sensor signals
burrs without having to redo the entire deburring process. were configured and synchronized to the virtual robot con-
The quality check is repeated until all the quality conditions troller I/O System and are illustrated in Fig. 5.
are completely satisfied. In the next section this approach is
further discussed and more details concerning the algorithm
Robotic deburring algorithm for partially removed
are provided.
burrs
In the 3rd Stage, the robot equipped with the vacuum
gripper approaches the deburred part secured in the vacuum
The tool employed in this work is a passively radial compliant
supporting frame. Then the robot proceeds to pick-up the
tool, which is particularly adept at flash removal. It is also
part and comes closer to the out-feeder conveyor. A proxim-
suitable for edge deburring and removal of parting lines. The
ity sensor (S5) placed on the conveyor confirms that it is clear
workpiece is a large sized 900 mm x 1800 mm injection
and safe for the robot to place the part on the conveyor. When
molded plastic part.

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Fig. 5 Cell signals configuration in the robot controller

Taking into consideration the size of the workpiece a solu- the video detected burr. Finally, the program is synchronized
tion to deburr only leftover burrs rather than re-doing the to the robot controller.
complete workpiece profile, can assure an important time The vision system employed in the visual inspection rou-
reduction to finish the workpiece and also benefits by an tine consists of a high acquisition speed VGA camera. Its
energy-wise approach. The workflow implemented is illus- compact size (35 mm x 32 mm x 75.5 mm) makes it suitable
trated in Fig. 6 and certifies that all the burrs have been for integrating it into tight spaces on the robot and mounting
successfully removed. it inside the master flange of the ATC system. The camera
The proposed algorithm uses image processing to identify model used is Cognex 8400 (embedded with image process-
partially removed burs and establish the areas to be machined. ing), having a resolution of 640 × 480, max acquisition speed
Leftover burrs may occur during deburring due to the pecu- of 217 fps, Gigabit Ethernet connectivity and Power supply
liarity of the tool with radial compliance which will deflect Ethernet (PoE). A connection with the robot controller can
in a direction perpendicular to the cut when thicker burrs are be established via the robot controller’s Integrated Vision
encountered. The proposed deburring algorithm is used to Interface. The vision system provides targets in a coordinate
detect only the location of the partially removed burrs and system shared with the robot. The RobotStudio environment
machine those areas in multiple passes (iterations) based on offers a toolset for part location and inspection. The authors
burr height and tool cutter radius. The block “New deburring configured and fine-tunned a vision job by defining the part
process” from Fig. 6 illustrates the routine which consists of the camera should locate, the inspection tool, and how the
multiple deburring passes. vision data is transferred to the robot program, employing
Most papers found in the literature for robot paths gener- the already defined Robot TCPs.
ated based on image processing either don’t cover the use of A crucial prerequisite for the vision job is to calibrate
passively radial compliant tools (rather use an active compli- the image to real-world units [mm] by using checkerboard
ance system) or the use case of large-sized workpieces with calibration plates with fiducial. When executing the visual
uneven burrs. Having the same approach of generating mul- inspection routine, the robot reaches the same position (rob-
tiple passes based on burr height and tool cutter radius for target) every time an image is acquired. Given its large size,
the full workpiece, for the studied use case, it would result in the workpiece has been divided into 6 views of interest. Each
a longer machining time and robot energy inefficiency since view has a designated position the robot must reach and
most of the burrs are removed in the main deburring routine. acquire an image that is next matched to its corresponding
To further optimize the generated robot tool path, taking reference portion of the workpiece by employing the Robot-
into account the workpiece symmetry and burrs location, the Studio vision job.
algorithm also provides the required data for robot tool posi- In terms of excesive burr identification the coordinates of
tioning and routines to safely approach the workpiece and A, B, C, D, L, M, N, P and Q points are extracted (Fig. 8). The
to retract. For this study, there are four possible cases where input values are the coordinates of the previously mentioned
partially removed burrs can be located: left or right side of points and the mill radius Rm . The L point locates the part in
the workpiece and on the outer or inner part. Thus, based the XOY reference coordinate system.
on the XY coordinates of the detected burr, a safe routine A reference workpiece was used in the vision job as model
to approach and to retract from the workpiece can be gener- for the location tool to determine the position of the work-
ated. The toolpath is created based on the shape and size of piece in XY coordinates as a fixture point. The location tool

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Journal of Intelligent Manufacturing (2023) 34:2765–2781 2773

Fig. 6 Comprehensive
representation of the deburring
workflow

coordinates. This information is used to determine the corre-

sponding robot routines to approach and retract. A minimum
area restriction was specified for the blob presence tool to
filter out noise. The edge defect detection tool uses an array
of calipers for precise locations of edge features and reports
if deviations are found in the region of interest relative to
the part fixture point. The max deviation (representing the
burr height – point P and Q) and the min deviation (repre-
senting the burr length – point B and A) are reported in XY
coordinates.
In the first stage the algorithm removes the excessive con-
vex burrs starting from Q point. The maximum limits are
defined by A, Q, P and B point coordinates. The machining
strategy assumes to remove the excess material by successive
milling passes parallel to the AM edge of the piece and then
Fig. 7 Main robot programm routines to deburr leftover burrs parallel to MB edge. Therefore, the material to be removed
is divided in cutting depths equal to the tool radius. Starting
from the Q and P points, that are the extreme limits of the
tool path, the algorithm calculates the next trajectory using
is part of the RobotStudio toolset for visual inspection which the Q and P coordinates and the tool radius Rm. The compu-
employs a pattern finding process consisting of two phases: tation continues until the distance from the last point to the
training and finding. In the training phase, a region containing AM edge is less than the tool radius, when the contact point
the reference workpiece pattern to be located was manually between the tool and the part is assumed to follow up the AM
identified and extracted to create a trained pattern. In the and MB segments, respectively (Fig. 8).
finding phase, new images of inspected parts are searched
for positions that exhibit maximum similarity (according to Robot energy consumption
the specified metrics). Corner points (M and N) are defined
on the reference part while the location tool enforces their For the deburring workcell, in an effort to optimize the robot
position on the inspected part by matching the pattern feature program energy-wise, several simulations have been per-
of the inspected part and its reference. formed, to monitor and record the energy consumption with a
Another matching pattern process was employed to com- tool that accurately evaluates the energy consumption. Nev-
pare the inspected part to its reference to determine and to ertheless, as any simulation model that uses approximations,
highlight the remaining defects using a bilinear pixel com- the energy data recorded is slightly understated, as we expect
parison method. Using this information, two other tools are electromechanical losses in robot drives and operating con-
employed: the blob presence and the edge defect detection dition influences to be oversighted by the software model.
tools. The blob presence tool performs a pixel connectivity For the virtual robot, the signals of Total Motor Power and
analysis in the region of interest relative to the part fixture Total Motor Energy are based on an ABB robot during typical
point. Its role is to locate the highlighted defects (light- operating conditions. The purpose is to identify power usage
colored connected pixels on a dark contrast, according to peaks and to adjust the robot program in order to reduce the
a specified threshold) and report their center position in XY power consumption.

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2774 Journal of Intelligent Manufacturing (2023) 34:2765–2781

Fig. 8 Computational model for

deburring excessive burrs. 1 -
workpiece with excess burrs; 2 -
burrs detail and toolpath; 3 -
image processing (burrs - green)

As illustrated in Fig. 9, a record where the total energy Fig. 9 (2), the deburring of excess burr requires 3 consecu-
consumption and the total absorbed power for a single work tive passes. When employing a compliant tool, the maximum
cycle has been analyzed for a workpiece where burrs were excessive burr that can be removed at a single pass is equal
successfully removed from the first stage of the deburring to the tool radius.
process (1), as well for a workpiece where additional debur- The recorded data for a simulated work cycle demon-
ring routines were required to remove remaining burrs (2). strates how the robot speed and payload have an impact on the
Successfully deburred means that the robot visual inspec- energy consumption. By raising the payload, the energy con-
tion didn’t identify any remaining burrs along the workpiece sumption is increasing accordingly and higher or very slow
profile. Figure 9 (2) illustrates the energy recorded during speeds lead to augmented energy consumption. Thus, the
a work cycle of a workpiece for which the robot visual offline simulation brought a trade-off between the reduction
inspection identified a single area where burrs have been of the energy consumption, achieving quality and productiv-
partially removed, and the proposed algorithm generated ity requirements as well. Figure 10 shows the total energy
a second deburring routine focused only on the identified consumption report for a workpiece without remaining burrs
area. after the first deburring operation (1), for a workpiece with
An important time in this additional machining phase is remaining burrs that requires a second deburring operation in
consumed by the robot to change the tool and to reach the which our solution was employed (2), and one that requires
position for this new routine. It is presumed that burrs that a second deburring operation repeating the entire part pro-
are not entirely removed in the main deburring routine are file (3). A validation of the simulation results is possible by
thicker, causing the compliant tool to deflect, and success- comparing the data with physical records from actual mea-
fully removing them would require multiple passes. In the surements.
presented case study, the number of additional machining
passes was calculated in respect to the tool radius. This is
the reason why in this particular case the trajectory was not
much shorter in the second deburring phase. As illustrated in

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Journal of Intelligent Manufacturing (2023) 34:2765–2781 2775

Fig. 9 Records of the total energy (marked in black) and total power (marked in orange) of the drive for the deburring process during a work cycle
of a workpiece with no remaining burrs (1) and with remaining burrs (2)

Fig. 10 Total energy

consumption report for a
workpiece with no excess burrs
(1), with excess burrs removed in
three consecutive passes
generated by the proposed
toolpath algorithm (2), and with
excess burrs removed in 3
consecutive passes along the
workpiece profile (3)

Web based platform for robotic deburring and GUI elements are used to present the information in
cell remote control and monitoring interactive charts and to be used for KPI reports. A messag-
ing system is employed to trigger condition-based alerts with
A web-based approach for a manufacturing monitoring sys- appropriate instructions. Based upon this data, authorized
tem allows the use of a wide range of devices with graphical people can take informed decisions concerning the produc-
interface support, but also has its drawbacks which are further tion system. All sensor signals have a digital copy in the
discussed. The novel web platform was developed to access virtual controller, as exhibited in Fig. 5. The virtual model
information from the virtual robot controller via web ser- simulates the robot behavior in the real world and provides
vices which follow the architectural form of RESTful APIs feedback. The virtual model simulates the robot behavior in
using the HTTP protocol while the messages are composed the real world and provides feedback since it can calculate
of XHTML and JSON. A user authentication is required via robot motions and handle I/O signals. Figure 11 illustrates
login data, such as username and password, which are defined the required components of the web platform.
in the virtual controller. The data is stored on a local server

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Fig. 11 Web-based robotic manufacturing platform for monitoring and control

The user interface consists of seven main parts illustrated energy consumption, breakdowns or decreases of the daily
in Fig. 13: • the 1st section allows authorized personnel to delivery in the manufacturing batches.
select the robot controller unit to connect with (in this case,
a connection to the virtual robot controller was made); • the Web platform alerts
2nd section displays a 3D model of the selected workcell; •
in the 3rd section, the robotic deburring process can be moni- For triggering and sending customized notifications and pre-
tored via a livestream of the DT, or alternatively by switching set alerts to authorized users, a bot messaging method was
to a live recording of the real workcell supplied by a camera chosen as it can be easily integrated with a database. A Tele-
with 2 (tilt-pan) DoF; • the 4th section illustrates the remote gram bot is a small program that can embed in Telegram chats
control board, which allows authorized personnel to stop the and perform specific roles. Additionally, authorized person-
process in case of emergency and allows control over the DT nel can also react fast and accomplish specific actions when
simulation (such as starting, stopping, or resetting the virtual a notification is received. A sample of the received message
simulation); • the 5th section illustrates the remote monitor- alert is illustrated in Fig. 12 reporting unexpected peak energy
ing board, where the current state of selected manufacturing consumption along with two possible options for the user to
process sensors is displayed; • in the 6th section, an Energy act in response.
Consumption interactive graph is displayed • the last section
is an interactive manufacturing volume graph. System alerts
can be set based on the recorded data in case of abnormal

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Journal of Intelligent Manufacturing (2023) 34:2765–2781 2777

Industry 4.0 context. Future work may be focused on the

cyber-physical security and other KPIs driven events that can
be implemented as the web-platform is designed to easily
grow into a System of CPRSs.

Discussion of the results

The paper encompasses the development of a DT for a robotic

deburring cell together with a web platform for remote mon-
itoring and control. The work offers to research engineers
the necessary means to tackle the innovative challenges of
Industry 4.0 by setting up an environment where they can get
a hands-on experience on concepts such as CPS, virtualiza-
tion and interoperability concerning workcell components.
Upon that, they can use the web platform and further experi-
Fig. 12 Telegram bot for alerts - phone screenshot ment with continuous control principles and data acquisition
from the robot controller or easily scale the monitoring sys-
tem across multiple robotic cells. Moreover, the work offers
Remote monitoring and control the tools and space for engineers to practice and develop
intelligent solutions for robotic machining.
The design of a monitoring system involves interdisciplinary The platform is currently employed in training and teach-
skills with regards to data acquisition, data storage, etc. for ing activities in EUR-ACE labeled Robotics bachelor and
both the hardware and software aspects. A data storage mod- master study programs running at the Faculty of Indus-
ule is responsible for data archiving, distribution, and storage. trial Engineering & Robotics from Politehnica University
For the present web platform, the data stream was stored on of Bucharest. The training program enables the students to
a local server in JSON format and continuously synchro- increase their understanding of the principles and operation
nized to the web platform. Various factors were considered of industrial robots used in modern manufacturing applica-
such as data-streaming speed, storage size, and exchange- tions. Through project-based teaching, the students get an
ability as they are some of the key factors to be considered in insight into the design and control principles of industrial
order to establish the efficiency of a production monitoring robots and robotic workcells (CAD & OLP), a hands-on
system. Monitoring the system close to real-time demands experience working with software applications used in the
good quality data-streaming speed (bottlenecks could occur manufacturing environment, and a PLM engineering per-
on both software and hardware sides). These factors deter- spective. The platform is also employed for programming
mined the time intervals at which the energy data is collected, tasks of the electrical driving systems, for the definition of
for how long it should be stored and whether compressing the working cycles and to determine the speeds and the
methods should be used, correlating with the storage space travel distances of the pallet during the work cycles. A
needed. study concerning the robotic engineering education in the
In the visualization module, where charts are presented, context of Industry 4.0 was published in (Nicolescu et al.,
the collected data (i.e. energy, completed parts) is plotted in 2019).
time order. The main purpose of a visualization module is The paper also covers the offline programming of the
to present complex data in a simple way to allow rapid and robotic workcell along with an original solution for optimal
efficient decisions to be taken by the supervising personnel. deburring of excessive burrs. Although the main challenge
By comparing the actual data with guidelines, authorized of using industrial robots for milling processes is their lack
operators can draw conclusions whether the manufacturing of stiffness, modern solutions such as tools with radial or
process is stable and effective. axial compliance together with smoother tool trajectories
The actions implemented to the web platform presented and advanced improvements in accuracy and stiffness com-
in this paper allow authorized remote control-access over the pensation methods can ensure that workpieces are machined
manufacturing process with the ability to stop the process in within intended tolerances. Generating robot trajectories via
case of an emergency, as well as the capability to stop or to image processing solutions were proposed in recent research
restart the robot controller. The proposed web-based platform for robotic deburring. However, all the achievements were
was focused on providing a remote control and monitoring focused on generating the complete toolpath without taking
system for Cyber Physical Robotic Systems (CPRS) in the into consideration drawbacks when using radial-compliance

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Fig. 13 Web based platform for remote monitoring and control of a robotic deburring cell. 1&3 - expected energy consumption and productivity;
2&4 energy consumption peak with a decline in productivity followed by a breakdown period

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Journal of Intelligent Manufacturing (2023) 34:2765–2781 2779

tools, such as the possibility to remove burrs only par- nature of the current technology used to develop the web plat-
tially. From this perspective, the paper presents an improved form brings to light another possible limitation of this study:
method that is beneficial in this application for large work- the remote-control functionality only allows authorized per-
pieces. A new robot programming solution based on image sonnel to stop the robotic process in case of emergency due
processing was implemented to safely re-machine only areas to the typical operation mode of a robotic FMC since the
where burrs could not be completely removed in the main remote control is restricted in the programmed task.
deburring routine.
The DT offers a good opportunity to better understand
how the robot work cycles have an impact on the energy
consumption. EC is getting considerable attention as EC Conclusions
models and optimization approaches are very well covered
in recent studies since the energy-efficient use of IR has a The present work illustrates key concepts of modern man-
great impact on the production costs. Moreover, the work ufacturing such as virtualization, smart energy-aware robot
highlights the essential knowledge for modern robotic man- programming, data acquisition, process monitoring and con-
ufacturing on energy-aware robot programming. Since there trol in a synergic approach. The aim of this research was to
are several methods for reducing the energy consumption develop the Digital Twin of a robot deburring cell together
of IR discussed in the literature, this work followed another with a web platform to continuously monitor the manufac-
perspective on energy-efficient motion planning along with turing process, to allow authorized control on the physical
signal-based scheduling optimization. workcell for emergency stop, to alert on unexpected event
The main goal of the presented web platform was to occurrences, to track the workcell productivity and part qual-
conceive a simple and efficient way to monitor a robotic ity, and to provide relevant and trust-worthy information that
manufacturing system in real-time in an industrial setting, can be used for KPI reports.
by presenting the data collected from the virtual controller The following aspects have been considered in this paper:
in history-based visualization modules, focused on robot • The deburring algorithm which uses image processing
energy consumption, as well as workcell productivity, to to identify partially removed burrs and decides the areas to
notify authorized personnel on pre-set alerts and provide be machined.
the means to react accordingly. With the use of a secure • Ensuring a successfully deburred workpiece employing
remote connection, the remote control can be easily extended a tool with radial compliance, while minimizing the energy
to allow the remote transfer of the programs to the robot consumption.
controller. Before the COVID-19 pandemic, the authors did • The web platform to remotely monitor the robotic
not consider the need of an extended remote control over a deburring process (tracking the energy consumption and the
robotic manufacturing process and did not acknowledge the number of machined parts), allowing remote control over the
necessity to perform remote work in the robotic manufac- robot to authorized personnel.
turing system. Certainly, expanding the remote control of a A CAD-CAM environment was used to design a digital
robotic process is now a possible direction for future work. copy of a physical robotic deburring cell, to set up a virtual
The system can be extended to collect, visualize pro- robot controller along with all workcell digital sensor signals,
cesses, and analyze data across the factory floor, making to plan the manufacturing process and to program the robot.
it central for operations. Real-time production data and The challenges of modern robotic milling along with energy-
call-to-action alerts help improve operational efficiency and aware strategies for industrial robotics, benefits of and threats
cost-effectiveness. The robot-based manufacturing system to remote-monitoring solutions were also discussed.
can be improved by the wireless sensor network to acquire The available equipment enables the authors to continue
the dynamic status and queries, and then be driven by remote the work with new developments of intelligent strategies
control methods towards trustworthy performance using AI for digitalization, energy-aware trajectory, and process plan-
procedures and machine learning algorithms. The feasibility ning, along with robotic specific cloud technologies for
of future implementations was also reported in the literature monitoring, control, and smart decision-making. Work is
(Wang & Wang, 2021). in progress to extend the web platform to remote-monitor
A possible limitation in this study that could be addressed and control new robotic systems, to develop and imple-
by future research is that the proposed deburring algorithm ment other Industry 4.0-specific solutions such as machine
has been purposefully developed to complement passive learning techniques for robot programming, as well for pre-
compliant deburring tools. These are not assisted by a 6- dictive maintenance and security defenses. The system can
DoF force & torque sensorial system, which is mandatory be expanded to collect, visualize processes, and analyze data
for tools with an active control system, as their main perk is across the factory floor, making it central for operations.
to fully remove burrs while respecting part tolerances. The

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Acknowledgements This work has been funded by the European Fund Hansen, C., Öltjen, J., Meike, D., & Ortmaier, T. (2012). Enhanced
from the Sectorial Operational Programme Human Capital 2014–2020, approach for energy-efficient trajectory generation of industrial
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