Lecture

Fundamentals of Robotics

F
Robot Programming – Part 1

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 1

 Methods for Programming Industrial Robots

Teach-In (Online) programming

with Teach Pendant

Playback (Online) programming

by moving the robot manually

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 Methods for Programming Industrial Robots

Offline programming
based on CAD-models of the workpieces
and a simulation model of the robot cell

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 Methods for Programming Industrial Robots

Methods for Robot

Programming

Online-Programming Hybrid Offline-Programming (OLP)

CAD- CAD-
Teach-In Playback Textual
based based
interactive automatic

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 Teach-In (Online) Programming
of Industrial Robots

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 Teach-In Programming

Characteristics
Programming takes place at the robot’s working site
Manual positioning of the robot

Program File Frame File

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 Teach-In Programming

Characteristics
Programming takes place at the robot’s working site
Manual positioning of the robot

Program File Frame File

source: LAR

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 Teach-In Programming

Characteristics
Programming takes place at the robot’s working site
Manual positioning of the robot

Program File Frame File

source: Hochschule Osnabrück

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 Teach-In Programming: Teach Pendants

source: ABB

source: KUKA

sources: Adept, Stäubli, Cloos, Reis/KUKA

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 Teach-In Programming: Functionality of a Teach Pendant

Emergency stop Buttons for moving the robot:

 Single internal axes
Switch for
 External axes
operating modes
 Cartesian coordinates
 Different coordinate sys.

6-D mouse
Programmable
soft keys

Dead man's
switch
Alphanumeric
keypad

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 6D-Mouse

forward / backward
left / right
up / down

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 Teach-In Programming: Steps of creating a program

Definition of a point variable (“robtarget”) in the robot controller program

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 Teach-In Programming: Steps of creating a program

Moving the TCP to a desired point by using the Teach Pendant

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 Teach-In Programming: Steps of creating a program

Storing coordinates into the variable

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 Teach-In Programming: Steps of creating a program

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 Teach-In-Programming with a Teach-Pendant in 2019

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 Playback (Online) Programming
of Industrial Robots

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 Online Programming: Playback Methods

Moving the Robot directly

Moving an auxiliary kinematic

for storing motion coordinates

Moving the Robot by moving a

kinematic model simultaneously source: Bartenschlager / Hebel / Schmidt

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 Play Back: Moving the Robot

source: Kroth/REIS
Teaching with a 6D-Mouse at the Effector

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 Play Back: Moving the Robot with a 6D-Mouse

source: Kroth/REIS
Teaching with a 6D-Mouse at the Effector

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 Play Back: Moving the Robot with Weight Compensation

source: Rethink Robotics

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 Play Back: Recording Motion Coordinates

Programming user frames with a 3-D measuring arm

source: Brechmann-Guss (Creative Commons)

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 Play Back: Using a Kinematic Model

Tele-manipulating Justin at DLR

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 Teach-In Programming

Characteristics
Programming takes place at the robot’s
working site
Manual positioning of the robot by eye
(with visual judgement)
bent, twisted, crash?
Advantages
+ Inaccuracies of robot system are considered implicitly

Disadvantages
- Production downtime
while programming
- Time duration of programming
- Accuracy / Quality of processing
- Safety for the programmer
- Qualification of the programmer
Roller for road construction

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 Teach-In Programming

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 Offline Programming (OLP)
of Industrial Robots

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 CAD-based Offline Programming & Simulation

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 CAD-based Offline Programming & Simulation: Principle

User Interface
CAD-Daten

Simulation Model

Workpiece Periphery
Tool model Robot model
model model, e.g. jigs

CAD-Geometry + Kinematic information

Offline Programming Functions

Robot program

Code adaption

Graphical simulation

Robot controller

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 CAD-based interactive OLP: Major Components

Database
CAD-Kernel External Work-
Robot Positioner Tables Tools Sensors Programs
axes pieces

Modeling
Offline-Programming
Graphics / CAD Functionality

Teach-In
Graphical
Programming at the
CAD-model

Visualization
Program Generator  CLOOS, KUKA, FANUC, ABB, etc.

Interfaces Kinematics Simulation

Inter-
STEP, ACIS, preter
Parasolid, etc. Transformations Path Planning Animation Collision Control

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 CAD-based interactive OLP: Operation

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 Subassembly to be welded – Pure Geometry Model

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 Subassembly to be welded –
with Weld Seams and Motion Points

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 CAD-based automatic OLP: Major Components

Database
CAD-Kernel External Work-
Robot Positioner Tables Tools Sensors Programs
axes pieces

Modeling
Offline-Programming
Graphics / CAD Functionality

Teach-In at the
CAD-model
Technology Modules

Welding Cutting
Grafical
Programming Ship Profile
Narrow
Pipe 3D Profile Sheet …
Gap

Sensor Integration (Laser-triangulation, Arc-sensor, Tactile, 3D Cameras)

Visualization
Program Generator  CLOOS, KUKA, FANUC, ABB, etc.

Interfaces Kinematics Simulation

Inter-
STEP, ACIS, preter
Parasolid, etc. Transformations Path Planning Animation Collision Control

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 CAD-based interactive OLP ↔ CAD-based automatic OLP:
Characteristics

Graphical Offline-Programming

CAD-based interactive OLP CAD-based automatic OLP

 Teach-In on the screen  Automatic processing of CAD-

workpiece-models
 Manual definition of motion
paths point by point  No or minimal interactive work at
the computer
 Manual generation of auxiliary
motions  Automatic generation of motion
paths for part processing and
 Interactive generation of measuring
controller program source code
 Automatic generation of
 Interactive simulation and controller program source code
collision control.
 Automatic simulation and
collision avoidence.

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 35

 CAD-based interactive OLP ↔ CAD-based automatic OLP:
Advantages / Disadvantages

Interactive Offline-Programming
+ Reduced robot downtime
- Very time consuming
- Poor Integration of process knowledge
- Quality of processing
- No automatic program generation
- High Qualification of the programmer required
- Re-teaching of frames often required.

Automatic Offline-Programming

+ Almost no robot downtime

+ Very fast
+ Automatic adaption of robot motions to the process based on
technology rules
+ Automatic parameter identification from data bases
+ Automatic measuring strategies
- Additional costs.

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 36

 Classification of OLP-Systems regarding the developer
(robot manufacturer ↔ independent developer)

Robot brand (manufacturer) specific systems

+ Cheap if supplied with robot
+ Simulation accuracy
(exact characteristics of robot + controller,
utilization of original controller software)
- Poor CAD-based program generation
(CAD interfaces and data processing)
- Poor Integration of process knowledge
- Poor Automatic program generation

Robot brand (manufacturer) independent systems

+ One system for several different robot types

+ Better CAD-functionality
+ Systems with fully automatic OLP available
- Additional costs

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 Learning Objectives – Robot Programming

 Please give an overview of the different programming methods for industrial

robots. Please explain each one in a few words.
 Please describe three different Playback-Methods in a few words.
 Name the characteristics, advantages and disadvantages of teach-in and
playback programming.
 Why are inaccuracies of robot systems considered implicitly by teach-in
programming?
 Please name the major components of CAD-based interactive offline-
programming systems and describe each in a few words.
 Please name the two different groups of OLP-Systems regarding the degree
of automation (of program creation) and their characteristics.
 Please name the advantages and disadvantages of interactive and automatic
offline-programming.
 Please name the advantages and disadvantages of robot manufacturer
specific and robot manufacturer independent offline-programming systems.

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