Lecture

Fundamentals of Robotics
(Automatisierungs- und Robotertechnik I)

F: Advanced Robot Programming

CAD Model Types
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 CAD – Based Automatic Robot Programming

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 Automatic Robot Programming: What do you have to know?

welding direction
Where exactly does the robot have to move to (Frames)?
Workpiece geometry  CAD-model
Distance to object  process knowledge
Orientations  process knowledge
Positioning and shape tolerances  measuring methods
Which motions does the robot have to perform (trajectories)? push welding neutral drag welding

Speeds  process knowledge

Sequences and directions  process knowledge 8 9 10
Joint configurations  motion planning / kinematics
Distribution of motions to 3 1

internal robot axes, gantry axes 7 2

6
and workpiece positioner axes  motion planning / kinematics 5 4

How can I tell the robot to perform these motions?

Robot controller program  language code generation
How do I know, that the robot is really able to perform the required motions?
 motion simulation
 reachability control
 collision control
What can I do, if a collision occurs between the robot and a workpiece?
 automatic collision avoidance.

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 CAD – Based Robot Programming

Control points

Workpiece
Contour1
Control-point1
Control-point2
Control-point3
Control-point4
Contour2
Control-point1
Control-point2
Control-point3
Control-point4
Control-point5
Control-point6
Control-point7
Control-point8
Control-point9
Control-point10
Contour3
Control-point1
Control-point2
Control-point3
Control-point4
Control point5

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 CAD – Models of a shaft

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 3D-data models

(IBM/Dassault)
Volcano jet engine of the Ariane 5 rocket.
Rendering: graphical processing  computing a picture with shadows + reflections
considering visual properties of the material and the surface textures.

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 Different Types of 3D-model Views (on the screen!)

Wireframe view Hidden line view

Shaded view Rendered view

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 3D-data models (stored „inside“ the computer!)
classified by information content

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 Example for the topology of a wireframe model (with relation tables)

(Vajna)

Topology is the relationship between geometric objects.

E.g. the property of a point being the endpoint of a line or the property of a surface enclosing a certain body.

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 Example wireframe-model: Shape lines of a car body (first conceptual design)

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 Example wireframe/surface-model: Shape lines of a car body

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 Comparison Wireframe Model  Surface Model

Wireframe model Surface model

Points, Lines Points, Lines, Faces

Wireframe model Surface model

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 Creation of 3D-surface models from 2D-contours

Extrusion / Translation Rotation Sweeping

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 Free Formed Surfaces

Polynomial representation
especially for car body design

Aesthetics or fluid mechanics

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 Definition of Free Formed Curves (Splines) I

Free formed curve (Spline)

interpolating  running exactly through the defining points

Spline through a sequence of points

approximating  balancing between the defining points

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 Methods for the Mathematical Representation of Free Formed Curves

Method Graph Math. Representation Weight Function

Polynoms

FERGUSON

LAGRANGE

Cubic
Splines

BEZIER

B-Splines

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 Free Formed Surface: Splines as defining contour and as guiding line

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 Approximating Free Formed Surfaces

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 Interpolating Free Formed Surfaces

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 Definition of Free Formed Surfaces with Free Formed Curves

Von Freeformer, CC BY-SA 3.0,

https://commons.wikimedia.org/w/index.php?curid=641986

Free formed surfaces are built segmentally by so called patches.

The patches can be defined by means of free formed curves:
a) e.g. by moving a constant or a variable cross contour [Q] along a guiding line [L] (sweeping)
b) Definition by intersection curves (in particular after digitizing a physical 3D-model)
c) Definition by boundary curves of a patch

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 Typical steps to create a CAD-surface-model from a physical model

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 Methods for the Mathematical Representation of Free Formed Surfaces

Method Graph Math. Representation Weight Function

Polynoms

LAGRANGE

Cubic
Splines

COONS

BEZIER

B-Splines

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 Solid Models

From Surface- to B-Rep-Model:

Workpiece

Wireframe model Surface model Boundary Representation model

(B-Rep)
Special kind of Solid model

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 Solid Models

Boundary
Representation
Model

B-Rep

Constructive
Solid Geometry
Model

CSG

(Bernatz)

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 Typical Primitives for CSG-modelling

Cuboid Cylinder Sphere Pyramid

Cone Torus Rotational solid Extruded solid

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 Boolean operations with solid primitives

Union Difference
Merger of two objects into one Subtraction of one object from another

Intersection
Portion common to both objects

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 Boolean operations with solid primitives

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 Workpiece-oriented Modeling

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 Addition and Subtraction of Volumes in Manufacturing Processes

Drilling Chipping
(subtraction of 3D-elements)

Welding Joining
Soldering
Bonding
(addition of 3D-elements)

Chipping
Milling
(subtraction of 3D-elements)

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 Different ways of modelling an object

Addition of primitives

Subtraction of primitives
from a solid Cuboid

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 Example for CSG-model (disk brake)

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 Example: Solid Model of a Cutter Head (Drilling Machine used for building Tunnels)

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 Conclusion: 3D-Geometry Models

Solid model
Wireframe model Surface model
Surface oriented Volume oriented

Points, Lines,
Points, Lines Points, Lines, Faces Volumes
Faces, Volumes
B-Rep (Boundary CSG (Constructive
Wireframe model Surface model
Representation) Solid Geometry)
(Spur/Krause97)

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 Combinations of 3D-Models (Hybrid Models)

Wireframe Surface Solid

Model Model Model

Wireframe Boundary CSG-

Surface Representation Model
Model Model

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 3D-Models

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 Data Exchange of two CAD-Systems

Exporting Importing
system system

Datenaustausch/
Schnittstellen

Data files Converter Data files

Exporting Importing
system system

Exporting Converter Converter Importing

system (Postprocessor) Neutral (Preprocessor) system
Data files

Data files Data files

Exporting Importing
system system

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 Direct interfaces

CAD
1

CAD CAD
5 2

CAD CAD
4 3

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 Neutral interfaces

Neutral Interface

Exchange model

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 Overview of CAD-Interface Standards

Geometry,
Drawing

CAD-
interfaces
Machine Product
Control Model

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 DXF-Interface

DXF (Autodesk AutoCAD)

Drawing Interchange File [Drawing Exchange Format]

Entities: Design and Drawing Elements:

Points, Lines, Circles, Arcs, Polylines, 3D-Faces, Solids, Vertices,
Dimensioning, Symbols, Text, Attribute Definitions and Block references

Tables: Properties of Entities,

e.g. Line Types, Layers, Fonts

Blocks: Groups of Associated Elements

Header: Administrative Information

DXF 2D: most important and widely spread industry standard

DXF 3D: not widely spread or accepted

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 Entities of IGES-Version 4.0

IGES: comprehensive
rather reliable
widely spread
since the 80s

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 VDA/FS – Example Car Body

VDA/FS:
 Limited to a few Geometry Elements
 Easy
 Reliable
 Widely spread in the 80s and 90s

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 Entities of VDA/FS Version 2.0

Single points

Set of points

Set of points with vectors

Polynomial Curve

Polynomial Surface

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 Origin of the STEP-Interface

Interface Standardization Committee

domestic

Standard
for the Exchange of
Product Model Data

STandard for the Exchange of Product model data

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 STEP

a) Presentation Model f) Views

b) Material Model

g) Topology Model

c) Model with Tolerances

 Very comprehensive Specification
 Covers the hole Lifecycle of a product
 Much more than only Geometry Data
 Replaces several national Standards
d) Model with surface properties
h) Geometry Model
 Widely spread
 Many good and reliable Implementations

e) Model with Form-Features

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 ACIS Solid Modeler and File Format

 Not an Interface, but a Solid Modeler with its own File Format (Spatial / Dassault)
 Combination B-Rep-/CSG-Modeler
 Supports complex Free Formed Surfaces as well as Boolean Operations
 Licensed by several CAD-System Suppliers
 Its File Format (.SAT) is supported by most of the popular CAD-Systems
 Has developed to a de facto Industry Standard.

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 Stereolithography – Interface (STL)

 Simplified File Format for the Creation of „3D-Printing“-Models (Additive Manufacturing)

 Surfaces approximated by Facets (tesselation)
 Closed Surfaces of Triangles with Normal Vector for each Triangle
 Sufficient for many purposes (viewing / AM)

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 Jupiter Tessellation (JT)

Source: Okino PolyTrans

 ISO-Standard visualization format

 JT files are inherently "lightweight" (~1-10% of the size of a CAD file)
 Facet data
 Complete NURBS geometry representations
 Geometry Primitives - box, cylinder, pyramid, sphere.

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 Loss of Data during transfer

Sending Receiving Sending Receiving

System System System System

Lost Data

Lost Data

Lost Data

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 Testing a CAD-Interface

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 Learning Objectives – CAD for Robot Programming

 Please explain the differences between a wireframe view and a wireframe model.
 Please explain the differences between a wireframe model and a surface model.
 Please name and explain three different methods to define a surface model of a
simple object. (20)
 Please explain the differences between a surface-model and a B-Rep-solid-model.
 Please explain the different ways to create a solid model
by B-Rep- or by CSG-modeling.
 Please describe the typical steps to create a CAD-surface-model
from a physical design model.
 Which method of CAD-modeling is also called workpiece-oriented modeling
and why?
 What is a Hybrid Model and for which applications is it used.
 Please describe the advantages and disadvantages of direct interfaces
and neutral interfaces.
 Please name the most important CAD-interfaces for offline-programming
of industrial robots.
 Please characterize each one with a few words..

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