Northeast Manufacturing News • Feb 19 • Toolbox For Industrial Robot Users

“Computer-based programming is the best way to maximize return on investment for robotic systems, resulting in lower costs, faster time to market and superior end products. ABB RobotStudio allows programming to be done on a computer without disturbing existing production,” said a company spokesperson.

System integrators can communicate better with customers and involve them closely through all phases of robot integration, from design through commissioning. The result is that integrators can deliver solutions faster and customers get systems with higher productivity at lower costs. Realistic graphics with accurate tooling, movements and throughput mean proposals are easier to understand and clearly communicate the benefits of the system.

“Given the complexity of modern robotic systems, it can sometimes be a daunting task to ensure all design elements are correct from the beginning. Computer-based system design in RobotStudio ensures it is done right the first time, with the ability to verify tooling, cycle times, work envelopes and product throughput before any construction begins in the real world,” said the spokesperson.

“Achieving optimized solutions is made possible because you can quickly and easily try multiple configurations on your PC. You can be certain your system will work properly in the real world after seeing it work in the virtual world. The end result is greatly reduced risk.”

RobotStudio is built on the ABB Virtual Controller, an exact copy of the real software that runs robots in production. “This ensures everything in the virtual world works exactly how it will in the real world, by using real robot programs and configuration files identical to those used on the shop floor,” said the spokesperson.

The processing power of the computer can be used to automatically generate paths based on supplied CAD models, resulting in enhanced end products.

New products can be added to existing lines in the virtual programming environment without disturbing existing production in the real world. For programmers, this method of programming is far more efficient and can be done without the pressure of time or the constraints of pre-existing equipment locations. By lowering the barriers to robotic integration through ease of programming, customers and integrators both see reduced costs and faster times to market.

“Increased uptime, improved productivity, faster time to market and better quality add up to a virtually instantaneous return on investment for RobotStudio,” said the spokesperson.

The features of RobotStudio are split into Basic and Premium functionality. The Basic functionality can be used free of charge whereas the Premium functionality requires a paid subscription. CAD converters and PowerPacs require separate subscriptions.

RobotStudio can import CAD data in a number of formats. With the available layout functions, users can position parts the way they want. Using Mechanism Modeler, users can model their own tracks, tools or grippers for use in RobotStudio simulations.

Smart Components offers a way of creating simulations by adding behavior to the simulated objects. It brings life to the graphical component libraries by the addition of Base Smart Components for basic motion, signal logic, arithmetic, parametric modeling, sensors and so on.

By using a CAD model of the part to be processed, it is possible to automatically generate the robot positions needed to follow a curve or edge of the geometry. The AutoConfiguration feature helps users to automatically define the robot arm configuration for a complete path.

Tools are available to tune an entire path. Users can smooth out the orientation, reposition and mirror the path to get the robot to do exactly what they want. Users can compensate the path for the radius of the tooling used.

The integrated robot program text editor allows users to view and edit programs loaded into their robot, either real or virtual. Its features include syntax and error highlighting, tooltips, automatic insertion of arguments and context-sensitive help for robot instructions. There is a data editor that allows tabular editing of program data. Users can debug the program by setting breakpoints, step through the program and watch variable values.

The Jobs feature lets users operate on a large population of IRC5 controllers in the plant. There are several actions that can be carried out by the Jobs function, for example, do a backup, synchronize the time of the robots, read RAPID data, get system information and much, much more.

Visual SafeMove is a 3-D-based configuration tool for SafeMove. The configuration tool allows safety zones to be configured and visualized using the 3-D graphics view. It is part of the Basic edition, which means it is free of charge. It works for both real and virtual robots.

“The IRC5 controller features True- Move that provides outstanding path following capabilities. When working with an ABB robot you can be confident that the robot will always follow the programmed path regardless of the programmed speed , ” said the spokesperson. In RobotStudio, the programmed path will be visualized to show exactly how the robot will move.

The Signal Analyzer records and displays signals from a robot controller, which makes it possible to optimize the robot program. For example, users can record robot speed, power consumption, I/O signals, TCP and joint values. Signal recordings can be exported to Excel for further analysis.

The Virtual FlexPendant allows users to control and monitor the virtual controller in the same way as the real controller. Operators can, for example, use it to preview user screens created with ScreenMaker which is a tool in RobotStudio for developing FlexPendant user screens without the need to learn the Visual Studio development environment and .NET programming.

The DirectX 11 based 3-D graphics engine in RobotStudio enables the user to customize the light set-up by adding and tuning the light sources available: ambient light, infinite light, spotlight and point light. The shadows cast by the objects, in combination with the built-in material library, gives a realistic touch to the visualization of results. In addition, users can define view points and create markups.

RobotStudio can create a 3-D interactive movie packaged in a standalone executable for showing and sharing a RobotStudio simulation to others who do not have RobotStudio installed. During replay, the speed can be adjusted to run faster or slower than real time. A slider can be used to jump directly to the simulation highlights.

The transfer function allows easy transfer of offline-created robot programs to the real robot on the shop floor. This means that users can transfer data from a virtual controller (which is offline) to a real controller (which is online). Users can also compare the programs of the real and virtual controllers.

A PowerPac is an optional addition to RobotStudio for certain application specific tasks.

For more information contact: ABB Robotics, Inc. 1250 Brown Road Auburn Hills, MI 48326 248-391-9000 www.abb.com/robotics