CN113681574A - Three-dimensional visual simulation and off-line programming system of robot for metal plate bending - Google Patents

Three-dimensional visual simulation and off-line programming system of robot for metal plate bending Download PDF

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Publication number
CN113681574A
CN113681574A CN202110972440.3A CN202110972440A CN113681574A CN 113681574 A CN113681574 A CN 113681574A CN 202110972440 A CN202110972440 A CN 202110972440A CN 113681574 A CN113681574 A CN 113681574A
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bending
robot
sheet metal
simulation
information
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游有鹏
王栎
何健
韩朝
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Nanjing University of Aeronautics and Astronautics
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Nanjing University of Aeronautics and Astronautics
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Priority to CN202110972440.3A priority Critical patent/CN113681574A/en
Publication of CN113681574A publication Critical patent/CN113681574A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B25HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25JMANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00Manipulators not otherwise provided for
    • B25J11/005Manipulators for mechanical processing tasks
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D43/00Feeding, positioning or storing devices combined with, or arranged in, or specially adapted for use in connection with, apparatus for working or processing sheet metal, metal tubes or metal profiles; Associations therewith of cutting devices
    • B21D43/02Advancing work in relation to the stroke of the die or tool
    • B21D43/04Advancing work in relation to the stroke of the die or tool by means in mechanical engagement with the work
    • B21D43/10Advancing work in relation to the stroke of the die or tool by means in mechanical engagement with the work by grippers
    • B21D43/105Manipulators, i.e. mechanical arms carrying a gripper element having several degrees of freedom
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D43/00Feeding, positioning or storing devices combined with, or arranged in, or specially adapted for use in connection with, apparatus for working or processing sheet metal, metal tubes or metal profiles; Associations therewith of cutting devices
    • B21D43/02Advancing work in relation to the stroke of the die or tool
    • B21D43/04Advancing work in relation to the stroke of the die or tool by means in mechanical engagement with the work
    • B21D43/10Advancing work in relation to the stroke of the die or tool by means in mechanical engagement with the work by grippers
    • B21D43/11Advancing work in relation to the stroke of the die or tool by means in mechanical engagement with the work by grippers for feeding sheet or strip material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D45/00Ejecting or stripping-off devices arranged in machines or tools dealt with in this subclass
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D5/00Bending sheet metal along straight lines, e.g. to form simple curves
    • B21D5/004Bending sheet metal along straight lines, e.g. to form simple curves with program control
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B25HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25JMANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00Programme-controlled manipulators
    • B25J9/16Programme controls
    • B25J9/1602Programme controls characterised by the control system, structure, architecture
    • B25J9/161Hardware, e.g. neural networks, fuzzy logic, interfaces, processor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B25HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25JMANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00Programme-controlled manipulators
    • B25J9/16Programme controls
    • B25J9/1656Programme controls characterised by programming, planning systems for manipulators
    • B25J9/1661Programme controls characterised by programming, planning systems for manipulators characterised by task planning, object-oriented languages
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B25HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25JMANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00Programme-controlled manipulators
    • B25J9/16Programme controls
    • B25J9/1656Programme controls characterised by programming, planning systems for manipulators
    • B25J9/1671Programme controls characterised by programming, planning systems for manipulators characterised by simulation, either to verify existing program or to create and verify new program, CAD/CAM oriented, graphic oriented programming systems

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Robotics (AREA)
  • Automation & Control Theory (AREA)
  • Physics & Mathematics (AREA)
  • Artificial Intelligence (AREA)
  • Evolutionary Computation (AREA)
  • Fuzzy Systems (AREA)
  • Mathematical Physics (AREA)
  • Software Systems (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)

Abstract

A three-dimensional visual simulation and off-line programming system of a robot for metal plate bending is characterized in that: the bending machine comprises a device model library module, a device model selection positioning module, a sheet metal process simulation module, a bending system simulation module and a bending machine robot operation program generation module. The method is beneficial to meeting the application requirements of flexible processing process planning and off-line programming software of the sheet metal bending robot in the field of intelligent manufacturing.

Description

Three-dimensional visual simulation and off-line programming system of robot for metal plate bending
Technical Field
The invention relates to the field of robot simulation and offline programming systems, in particular to a sheet metal bending-oriented robot three-dimensional visual simulation and offline programming system. The method is used for improving the planning of the flexible machining process of the sheet metal bending robot and the vacancy of simulation software in the field of intelligent manufacturing.
Background
The sheet metal part has the characteristics of convenience in forming and good stability, is widely applied to various fields such as electric power, traffic, environmental protection, military industry and the like, and has important significance for realizing the automation and the flexibility of sheet metal processing and improving the production efficiency of the sheet metal part. With the continuous improvement and the accelerated updating of modern product requirements, the traditional sheet metal machining and manufacturing process is greatly challenged and mainly reflected in that:
(1) the workpiece bending process is complex, the planning of the bending process and the reasonable selection of process parameters put high requirements on the professional skills of operators, and the improper process selection directly influences the product foldability, the production efficiency, the precision consistency and the stability of the product and the like;
(2) the weight of large sheet metal parts partially used in the fields of environmental protection, electricity, engineering machinery and the like is large, the large sheet metal parts are often operated by multiple persons, the labor intensity is high, and the long-time continuous operation is difficult;
(3) certain safety risk inevitably exists in the manual working process, and unexpected health trauma of operating personnel also sometimes takes place.
With the rapid development and the popularization and application of the industrial robot technology, the automatic bending of the robot is brought forward and rapidly developed, the labor cost of sheet metal bending can be obviously reduced, and the production efficiency and the consistency of product quality are improved.
However, the operation programming of the existing robot bending is mainly through manual teaching: planning the operation action of the robot by a way that a craftsman operates the teaching box, recording the relevant information of all teaching points in the task execution process of the robot, and finally generating each operation motion control program for the robot to finish bending processing.
Compared with teaching programming, the robot bending off-line programming has the obvious advantages of improving programming efficiency, reducing equipment occupation time and cost and the like, can establish a robot bending processing system environment model consistent with an actual processing system by combining technologies such as CAD/CAM, computer graphics, robot motion planning and the like, and automatically generates and outputs the robot operation path information of bending processing through process analysis, simulation test, bending demonstration, path calculation and the like.
Disclosure of Invention
The invention aims at simulation environment establishment, whole bending process simulation and off-line programming in robot bending, and provides a three-dimensional visual simulation and off-line programming system of a robot for metal plate bending, and finally a control program of robot bending operation which can be directly used for actual production is generated. The system provided by the invention can effectively reduce the programming time and debugging time of the existing manual teaching, reduce the requirements of operators on the professional skills of bending process, robot programming and the like, greatly reduce the equipment occupation time in the manual teaching process, improve the automatic bending efficiency, and is particularly suitable for flexible automatic manufacturing of small-batch and various sheet metals.
The technical scheme of the invention is as follows:
the utility model provides a three-dimensional visual simulation of robot and off-line programming system towards panel beating is bent which characterized in that: it includes:
the equipment model library module is used for defining three-dimensional model file paths and key process parameters of each equipment required by the robot metal plate machining;
the equipment model selection positioning module is used for reading, matching and positioning a three-dimensional model of each piece of equipment required by the robot metal plate machining;
the sheet metal technology simulation module is used for reading sheet metal bending technology information and automatically calculating to construct a three-dimensional sheet metal model so that a sheet metal bending workpiece is bent and formed in a follow-up manner according to a bending planning procedure;
the bending system simulation module carries out overall operation path planning and visual simulation on the bending process of the robot through a bending control instruction generated based on metal plate bending process information, and is convenient for a user to check and verify the feasibility and the rationality of the bending operation of the robot;
and the bending robot operation program generation module is used for analyzing the bending simulation planning result and the bending robot operation path, and converting the bending simulation planning result into an instruction format of the bending robot to output.
The device model library module is established by the following steps:
the method comprises the following steps of firstly, carrying out three-dimensional modeling and local coordinate system definition on each device required by robot sheet metal machining based on SolidWorks and a CAD system, and storing the device in wrl file format, wherein the device comprises: the device comprises a bending machine tool, an upper bending die, a lower bending die, a sheet metal feeding and grabbing table, a sheet metal discharging and stacking table, a sheet metal centering table, a sheet metal turnover frame, joint elements of an industrial robot and a sheet metal gripper of the robot;
and step two, establishing a model database of each equipment according to the models, defining key process parameter data of each equipment, and using the database for rapid configuration of a selection scheme, function screening and model replacement of the robot automatic bending system in the equipment type selection process.
The equipment model selection positioning module is established by the following steps:
step one, two initialization schemes are provided in the equipment model selection process:
the first scheme is as follows: a plurality of sets of general bending environment templates are equipped and stored in the system, and can be directly selected according to the type of the processed sheet metal workpiece and the key parameters of the model;
scheme II: manually selecting the type of the equipment and initially positioning the equipment according to the actual processing environment;
reading and displaying three-dimensional model files of all component equipment of the robot bending system by using an open source Coin3D three-dimensional graphical interface library;
and thirdly, setting relative coordinates of each component equipment model in a world coordinate system by taking a Cartesian coordinate system of the bending machine tool as the world coordinate system, positioning and correcting the components and element models of the bending system to form a bending system simulation environment consistent with the actual robot automatic bending system, and locally storing the model selection and position data information in an xml format file to reduce repeated model selection and positioning work of the equipment.
The sheet metal process simulation module is established by the following steps:
step one, obtaining the information of a metal plate bending workpiece to be simulated at present, comprising the following steps of: the method comprises the following steps of selecting a scheme of sheet metal workpiece material performance parameters, workpiece thickness, two-dimensional geometric information of each expansion surface of a workpiece, bending edge process information, sheet metal bending process information and a grabbing base surface;
step two, converting the bending information into a data format special for a cost system and storing the data format;
and step three, performing initial construction of the three-dimensional sheet metal workpiece in a simulation interface according to the data information in the step two, rotating base planes on two sides of the bending edge around the bending edge in the simulation process through the bending information provided by each bending procedure, and calculating the curved surface length of the bent edge after the inner side and the outer side are bent to perform three-dimensional entity construction so as to form a vivid workpiece bending simulation effect.
The special data format for the bending workpiece information is characterized in that a center point of a captured base plane is used as a reference workpiece coordinate system of the sheet metal part, a bending edge sequence linked list based on bending processes is established, and each process data information comprises base planes on two sides of the bending edge, center coordinate information of the base planes relative to the reference coordinate system, a sheet metal bending edge bending angle and bending position data information.
The bending system simulation module is established through the following steps:
setting feeding and grabbing operations required in a simulation process of a bending system to determine an initial placing position and a grabbing and grabbing posture of a sheet metal workpiece to be simulated; the setting information comprises but is not limited to the translation position of the sheet metal workpiece coordinate system and the safety height of the gripper compared with the coordinate system of the feeding grabbing table;
setting the centering operation required in the simulation process of the bending system so as to simulate the secondary calibration and grabbing operation of the robot gripper on the bent sheet metal part in the actual machining process; the set information comprises but is not limited to the precise grabbing plane position and grabbing angle of the grabbing hand relative to the coordinate system of the sheet metal workpiece to be bent;
step three, performing path planning calculation on bending operations of each procedure required in the simulation process of the bending system, analyzing the position information of each bending required to move to the bending machine through the stored bending information of the bending workpiece, simulating actual bending work, calculating a safe position point outside a working area of the bending machine, a safe point entering the bending machine and a point to be bent, and performing dynamic simulation on a three-dimensional model of each bending operation process;
setting blanking stacking operation required in the simulation process of the bending system, and firstly automatically calculating a forming bounding box of the bent sheet metal workpiece in the system to determine the placing position and the gripping posture of the bent sheet metal workpiece; the setting information comprises but is not limited to the translation position and the placing height of the sheet metal workpiece coordinate system compared with the blanking stacking platform coordinate system;
and fifthly, replanning an operation path for a collision position possibly occurring in the simulation process of the bending system, inserting a new safe point pose and ensuring that no physical collision occurs in the simulation process.
In the simulation process of the bending system, the bending operation of each procedure is calculated to simulate the actual processing process, and the method comprises the following steps: the automatic bending method comprises a feeding process of grabbing a workpiece by a robot gripper to a bending machine, a sheet metal bending forming process of pressing down a sliding block on the bending machine, a discharging process of driving the workpiece to move out of the bending machine by the robot gripper after bending is completed, and a sheet metal part turning process, a gripper replacing process and other robot automatic bending process processes according to a turning frame.
The bending robot operation program generation module is a general bending robot operation instruction format designed for solving the problems of coordinate system definition and different instruction formats of different robots, and the information of the bending robot operation instruction format comprises: point location information, motion information, control information; firstly, all path nodes of robot operation in the simulation process are obtained by summarizing the simulation scheme of the bending process of the robot generated by the bending system simulation module, then all the path nodes of the robot bending simulation are converted into the pose of the robot end effector, and the pose is converted into the required bending robot operation instruction to be stored and output.
The details are as follows:
the generation method of the equipment model library module comprises the following steps: firstly, three-dimensional modeling is carried out on each device or element for machining the robot metal plate based on general CAD systems such as SolidWorks and the like, and the three-dimensional modeling is stored in a wrl file format, wherein the devices include but are not limited to: the device comprises a metal plate feeding and grabbing platform, a metal plate discharging and stacking platform, a metal plate centering platform, a metal plate turning frame, a bending machine tool, an upper bending die, a lower bending die, joint elements of an industrial robot, a metal plate gripper, a gripper library and the like; secondly, calibrating a local coordinate system of each model, wherein each joint element of the robot is modeled according to D-H parameters, a 0 th axis (base) coordinate system is used as an overall reference coordinate system of the robot, and the rest axes are spatially positioned according to the base coordinate system and the relationship between the axes; establishing a local coordinate system of each equipment for robot sheet metal machining in a general bending environment in sequence, so that the visual representation and the rapid position finding of an operation object and a target pose in the robot bending operation process are facilitated; and finally, establishing a database of each equipment model according to the models, defining key process and performance parameters, and quickly configuring a selection scheme, screening functions and replacing the models of the robot automatic bending system in the equipment type selection process.
The generation method of the equipment model selection positioning module comprises the following steps: first, two device type selection initialization schemes are provided: according to the first scheme, a system is provided with a plurality of sets of general bending environment templates, and can directly select according to the types of the processed sheet metal workpieces and the key parameters of the models; scheme II: manually selecting the type of the equipment and initially positioning the equipment according to the actual processing environment; after the model selection initialization is completed, reading and displaying the three-dimensional model files of each device by using an open source Coin3D three-dimensional graphical interface library; and finally, setting relative coordinates of each component equipment model in the world coordinate system by taking a Cartesian coordinate system of the bending machine tool as the world coordinate system, positioning and correcting each component equipment of the bending system and element models thereof to form a bending system simulation environment consistent with the actual robot automatic bending system, and locally storing type selection and position data information in an xml format file to reduce repeated type selection and positioning work of the equipment.
The generation method of the sheet metal process simulation module comprises the following steps: firstly, obtaining the information of the metal plate bending workpiece to be simulated, including but not limited to: the method comprises the following steps that sheet metal workpiece material performance parameters, workpiece thickness, two-dimensional geometric information of each expansion surface of a workpiece, bending edge process information, sheet metal bending process information, a grasping base surface selection scheme, mold configuration and other information are stored in a data format special for the system; and then, performing initial construction of the three-dimensional sheet metal workpiece in a simulation interface according to the data information, rotating base planes on two sides of the bending edge around the bending edge in the simulation process through the bending information provided by each bending procedure, and calculating the curved surface length of the bent edge after the inner side and the outer side are bent to perform three-dimensional entity construction so as to form a vivid workpiece bending simulation effect.
The special data format for the bending information in the sheet metal process simulation module takes a center point of a captured base surface as an original point of a coordinate system of a reference workpiece of the sheet metal part, and establishes a bending edge sequence linked list based on bending processes, wherein each process data information comprises the base surfaces on two sides of the bending edge, and the center coordinate information, the bending angle and the bending position data information of the base surface relative to the reference coordinate system.
The bending system simulation module is designed by referring to a typical robot bending operation flow, wherein the typical flow comprises the following steps: the material loading snatchs, and the position is snatched in the centering calibration, bends and bend and follow the action, and sheet metal component turn-over, basic steps such as unloading pile up neatly specifically include: firstly, setting feeding and grabbing operations required in the simulation process of a bending system so as to determine the initial placing position and the grabbing posture of a sheet metal workpiece to be simulated; the setting information comprises but is not limited to the translation position of the sheet metal workpiece coordinate system and the safety height of the gripper compared with the coordinate system of the feeding grabbing table; secondly, setting centering operation required in the simulation process of the bending system so as to simulate secondary calibration and grabbing operation of a robot gripper on the bent sheet metal part in the actual machining process; the set information comprises but is not limited to the precise grabbing plane position and grabbing angle of the grabbing hand relative to the coordinate system of the sheet metal workpiece to be bent; performing path planning calculation on the bending operation of each procedure required in the simulation process of the bending system again, analyzing the position of each bending required to move to the bending machine through the stored bending information of the bending workpiece, simulating actual bending operation, calculating a safe position point outside the working area of the bending machine, a safe point entering the bending machine and a point to be bent, and performing dynamic simulation on a three-dimensional model of each bending operation process; then, setting blanking stacking operation required in the simulation process of the bending system, and automatically calculating a forming bounding box of the bent sheet metal workpiece in the system so as to determine the placing position and the gripping posture of the bent sheet metal workpiece; the setting information comprises but is not limited to the translation position, the placing height and the like of the sheet metal workpiece coordinate system compared with the blanking stacking platform coordinate system; and finally, replanning an operation path for a collision position possibly occurring in the bending system simulation process, inserting a new safety point pose and ensuring that no physical collision occurs in the simulation process.
The bending simulation process in the bending system simulation module calculates the bending operation of each procedure and simulates the actual machining process by using a three-dimensional model dynamic graph, and the bending simulation process comprises the following steps: the automatic bending method comprises the following steps of a feeding process of grabbing a workpiece by a robot gripper to a bending machine, a sheet metal bending forming process of pressing down a sliding block on the bending machine, a discharging process of driving the workpiece to move out of the bending machine by the robot gripper after bending is finished, a sheet metal part turning process according to a turning frame, a gripper replacing process and other robot automatic bending technological processes;
the bending robot operation program generation module designs a general bending robot operation instruction format for solving the problems of coordinate system definition, different instruction formats and the like of different robots by a simulation scheme generated by the collected bending system simulation module, and the information of the general bending robot operation instruction format comprises: point location information, motion information, control information, and the like; firstly, all path nodes of robot operation in the simulation process are obtained by summarizing the simulation scheme of the bending process of the robot generated by the simulation module of the bending system according to claim 1, then all the path nodes of the robot bending simulation are converted into the pose of the robot end effector, and the pose is converted into the required bending robot operation instruction to be stored and output.
The invention has the beneficial effects that:
the robot three-dimensional visual simulation and off-line programming system for sheet metal bending can perform visual modeling simulation on a bending environment; setting bending parameters and size information of the sheet metal bending workpiece, so that a three-dimensional model of the sheet metal bending workpiece can be established, and the three-dimensional model can simulate the bending of the sheet metal part according to theoretical sheet metal characteristics; according to the simulation bending environment and the three-dimensional model of the metal plate bending workpiece, referring to a typical robot bending operation process and relevant process settings, performing three-dimensional visual simulation, calculating and generating path nodes of the robot bending operation, and finally converting the result into an operation instruction format of the bending robot for storage and output through a program generation module.
Drawings
FIG. 1 is a system framework diagram of the present invention.
Fig. 2 is a diagram showing a relationship between local coordinate systems of the respective devices in the device model library according to the present invention.
Fig. 3 is a flow chart of the type selection of the device according to the present invention.
Fig. 4 and 5 are explanatory diagrams of chain data structures of bent workpieces according to the present invention.
Fig. 6 is a flow chart of system simulation according to the present invention.
FIG. 7 is a flow chart of a bending operation in a bending system simulation module.
Fig. 8 is a simulation demonstration diagram relating to the present invention.
Detailed Description
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below.
According to the figure 1, the embodiment of the invention provides a three-dimensional visual simulation and off-line programming system of a robot for metal plate bending, which comprises a device model library module, a device model selection positioning module, a metal plate process simulation module, a bending system simulation module and a bending machine robot operation program generation module; the system can be divided into a simulation environment configuration flow, a bending simulation flow and an off-line programming flow according to the five modules;
in the simulation environment configuration flow, the equipment model library module is used for completing the construction definition of three-dimensional files, local coordinate systems and key process parameters of all models required by the robot metal plate machining; the equipment model selection positioning module selects, reads and replaces each equipment file according to an established equipment model library to generate a bending environment model selection scheme, further provides three-dimensional files and key process parameter data of all models in the environment according to the bending environment model selection scheme, positions and corrects each component equipment and element models of the bending system to form a bending processing system simulation environment consistent with an actual robot automatic bending system, and generates a local xml file of the specified model selection scheme;
in the bending simulation process, three-dimensional model building is carried out on the simulation environment according to the established bending environment model selection scheme, the three-dimensional model building and displaying of the sheet metal workpiece can be carried out through the sheet metal bending workpiece information of the sheet metal process simulation module, in the bending system simulation module, two side base planes of each bending edge are sequentially rotated around the bending edge on the sheet metal workpiece according to the bending procedure planning result given by the sheet metal bending process simulation module and the bending information provided by each bending procedure, and the three-dimensional entity building is carried out by calculating the curved surface length after the bending edges are bent at the inner side and the outer side of the bending edge, so that a vivid workpiece bending simulation effect is formed. Based on the basis, the bending system simulation module further refers to a typical robot bending operation process to perform robot bending process simulation design, wherein the typical process comprises the following steps: the method comprises the basic steps of material loading grabbing, centering calibration grabbing position, bending and bending following action, sheet metal part turning, blanking stacking and the like.
In the off-line programming process, all path nodes of robot operation in the simulation process are obtained through the simulation planning result of the bending system simulation module, then all the path nodes of the robot bending simulation are converted into the pose of the robot end effector, and the pose is converted into the required bending robot operation instruction to be stored and output.
As shown in fig. 2, an embodiment of the present invention provides a method for setting coordinate systems of devices in a three-dimensional simulation environment of a sheet metal bending robot, where a local coordinate system setting relationship of the devices and a motion relationship between a sheet metal workpiece and a gripper are expressed as follows:
the simulation platform takes a bending machine tool as a reference coordinate system, and the coordinate system is relative to a geodetic coordinate system, and relative position coordinate systems of a sheet metal feeding and grabbing platform, a sheet metal discharging and stacking platform, a sheet metal turning frame, a sheet metal centering platform, an upper sheet metal mould, a lower sheet metal mould and a base (0 th axis) of an industrial robot are established relative to the bending machine tool; in the simulation process, the sheet metal workpiece is subjected to position conversion through a reference coordinate system provided by corresponding equipment in the processes of feeding, centering, bending, stacking, turning and the like, the follow-up operation of the gripper relative to the sheet metal workpiece is controlled in the simulation process, and the coordinate conversion of the gripper in the follow-up process drives the robot to change along with the six-axis joint elements except the base; the relative coordinate relationship of the sheet metal workpiece in each process flow in the bending simulation process can be efficiently analyzed and calculated through the set relationship of the local coordinate system, and the updating and the obtaining of the position information of each relevant element in the simulation process are greatly optimized.
Fig. 3 shows a device model selection process in an embodiment of the present invention, which includes the following specific steps:
first, two initialization schemes are provided: scheme one, general scheme template selection: the system is provided with a plurality of sets of general bending environment template reference schemes, a user can directly select templates according to the types of the processed sheet metal workpieces and the key parameters of the models, and the functions of equipment model replacement and the like are still supported after the selection is finished; and scheme two, comparing and selecting the type of the real scene: the user can manually select equipment and reproduce scenes according to the actual processing environment, but the model selection scheme requires the user to manually add data such as model library files and related process information; the system defaults to use a general scheme template scheme;
secondly, calling an equipment model library through the initialization scheme result, reading a three-dimensional original file of the selected equipment, and reading and carrying out simulation display on the equipment through an open source Coin3D three-dimensional graphical interface library;
after the three-dimensional file is read and displayed, the position of the displayed equipment can be corrected through a position information correction function provided by the system, the position information correction influences the accuracy degree of a simulation result, the position information of the equipment needs to be measured through a professional method, and the system is corrected by using a TCP (transmission control protocol) verification mode carried by a robot;
finally, after the positioning process of all the equipment models is completed, the system performs a one-key storage function, integrates the model selection scheme and the relevant process data of each equipment into a scheme file based on an XML format, and provides support for one-key loading and reading in the subsequent simulation process.
Fig. 4 and 5 show chain data structures of bent workpieces according to an embodiment of the present invention. Take a common six-base-plane five-bending square box shown in fig. 4 as an example, wherein: P1-P6 represent the bending base surface characteristics of the bending workpiece, and 1-5 represent the bending edge characteristics of the bending workpiece; wherein, each bending surface information comprises three-dimensional size information, central coordinate information and the like of the bending surface; the internal information of each bending edge comprises a bending angle of the bending edge, bending line position data information and the like, the chain type data structure is a bending edge sequence chain table based on a bending process, and each process data information comprises base planes on two sides of the bending edge, central coordinate information of the base planes relative to a reference coordinate system, a metal plate bending edge bending angle, bending reference pressing position data information and the like;
as shown by calibration of the bent sheet metal workpiece in fig. 4, the grabbing base plane of the bent workpiece is P2, the central point of the bent plane P2 is used as the origin of the reference workpiece coordinate system of the bent workpiece, and the reference coordinate system is used for sequentially making relative coordinate systems for the centers of the base planes P1 and P3-P6; the bending side is connected between the bending surface and the bending surface, the relative rotation relation between the two bending surfaces in the bending simulation process at each time is calculated through the bending angle of the bending side and the position information of a bending line, the relative coordinate system of the center of a base surface of the bending side is calculated and updated, the curved surface information of the bending side is also subjected to simulation calculation and updating, and the main body construction of the sheet metal workpiece and the dynamic three-dimensional reconstruction in the simulation process are performed through the chain type data structure of the bending workpiece in the simulation process.
In the design of the method, the bending edge is used as a main sequential structure, the grabbing basal plane is used as a reference basis, and a data chain structure describing the bending workpiece in the simulation process is established. The simulation difficulty of the system is mainly the following change of robot grabbing of the sheet metal workpiece in the simulation process and the workpiece bending change in the sheet metal bending process, wherein the following commands of the robot grabbing hand are all operated according to the process carried out by the sheet metal workpiece, the three-dimensional model information of the sheet metal workpiece can be effectively bound with the robot grabbing hand through the chain type data structure, and the simulation of the whole bending process and the dynamic entity transformation of the sheet metal workpiece are effectively realized according to the process information data of the bending edge.
Fig. 6 and 7 show a visualized simulated bending implementation process in an embodiment of the present invention, which includes the following specific steps:
firstly, reading a finished equipment model selection scheme file and sheet metal workpiece process data, importing and positioning a three-dimensional file into an equipment model according to an equipment model library, and automatically/manually selecting auxiliary equipment such as an upper die, a lower die, a gripper and the like according to the current sheet metal workpiece process data to finish the integral construction of a three-dimensional simulation initialization scene;
secondly, setting the links of material loading, grabbing and centering in sequence; the method comprises the following steps that a feeding grabbing setting link mainly relates to the determination of grabbing positions, and comprises the offset of a grabbing center of a grabbing hand compared with the grabbing base plane center of a bent workpiece in the horizontal direction and the vertical direction, the setting of feeding safety height, the setting of an ultrasonic detection switch required in the process of grabbing the bent workpiece in the real object grabbing process and the like; the centering setting link mainly relates to grabbing position deviation, grabbing angles and the like;
and thirdly, setting bending operation, wherein the bending operation mainly relates to calculating the bending operation of each process so as to simulate an actual machining process, the process comprises a feeding process that a robot gripper grabs a workpiece and sends the workpiece to a bending machine, a sheet metal bending forming process that an upper slider and an upper die of the bending machine are pressed downwards, a discharging process that the robot gripper drives the workpiece to move out of the bending machine after the bending is finished, a robot automatic bending technological process such as a sheet metal part turning process and a gripper replacing process according to a turning frame, gripper replacing and the like, and each operation process also needs corresponding technological information setting.
Setting all initial process information in the bending process is completed through the processes, then according to the graph shown in fig. 7, in the process of bending the robot gripper to the bending machine, firstly, the corresponding feeding position is found according to the bending edge indicated by the current bending process, the gripper posture is determined according to the bending position of the bending edge and the bending position of the lower die corresponding to the bending machine, a safety point is inserted in an auxiliary mode in the moving process of the robot, and collision is avoided in the feeding process; after feeding is completed, simulation bending operation of a current bent edge is carried out, the bending following process of an upper sliding block of a bending machine and a robot gripper is simulation of a real bending process, in the real bending generation, a metal plate workpiece can be bent very quickly according to the bending process in the pressing-down process of the upper sliding block of the bending machine, the gripper needs to follow up according to the bending process of the metal plate workpiece in the bending process, and the gripper refers to a coordinate system of the metal plate workpiece in the bending process to make corresponding posture change; the bent sheet metal workpiece in the working procedure needs to be moved out of a working area of the bending machine in the discharging process from the bent robot gripper to the bending machine, and a safety point needs to be inserted in an auxiliary mode in the moving process of the robot in the process of ensuring that collision cannot occur in the discharging process; after the material is discharged, namely the bending edge is bent, the subsequent bending operation or stacking operation process needs to be judged whether to turn over or change the grabbing base plane, when the turning over or the grabbing base plane needs to be changed, the current sheet metal workpiece needs to be moved to a turning frame, the binding between the grab and the sheet metal workpiece needs to be released, the grab operation is changed according to the requirement, the sheet metal workpiece is grabbed again according to the reset grabbing position, and at the moment, the grabbing base plane coordinate system and other base planes of the sheet metal workpiece also change; and then judging whether the sheet metal bending part completes all bending, if the sheet metal bending part still has an edge to be bent, repeating the operation, and if not, finishing the integral bending operation.
After the bending operation flow shown in fig. 7 is completed, the blanking stacking setting link shown in fig. 6 is returned, and the blanking stacking setting link mainly sets the blanking pose of the robot according to the sheet metal workpiece which is bent so as to ensure that the placing position of the bent workpiece is stable and the bent workpiece is not easy to overturn.
Then, carrying out integral visual simulation on the bending process, and sequentially simulating the whole flow of material loading grabbing, centering, bending and material unloading stacking; the simulation calculates the posture and the corresponding position of the gripper according to the completed operation setting, and carries out simulation movement on the robot and the sheet metal workpiece; the simulation process supports a single-step simulation scheme and a one-key automatic simulation scheme, interference points and serious error points can occur in the simulation process, and the system provides the functions of safe point insertion and path node deletion; and after continuously checking and determining that the simulation process does not have problems, recording all path nodes and outputting the path nodes to an offline programming module so as to finish the output of the instruction format of the bending robot.
And finally, calculating in a bending robot operation program generating module according to the generated path nodes to obtain a programming track of the gripper relative to the industrial robot, wherein the track point information comprises: point location information, motion information, control information, and the like;
the point location information includes: the spatial coordinate position and attitude of the current end effector relative to the current reference coordinate system, wherein X, Y, Z represents the spatial coordinate position of the current teach point relative to the current reference coordinate system, A, B, C represents the rotation angle of the current track point according to Z, Y, X to represent the current attitude, E1, E2, etc. represent additional axis-related information other than the bending robot, BASE _ NO 1 represents the device coordinate system to which the track point refers, for example:
X 370,Y 282.25,Z 101,A -90,B 0,C -180,E1 -700,E2 0,BASE_NO1
the segment information shows that the reference coordinate system number of the track point is BASE _ NO _1, the coordinate position of the reference coordinate system is (370, 282.25, 101), the posture of the track point needs to rotate to 90 degrees on the Z axis, 0 degree on the Y axis and 180 degrees on the X axis in sequence according to ZYX; and there are follower axes E1, E2 in the system, the E1 position is at-700 and the E2 position is at 0; information representation of the point is completed based on the above strategy;
the motion information comprises motion speed and motion mode; the movement speed is expressed by V, the unit is 0.001m/s, and the movement mode mainly comprises the following steps: linear trajectory motion LINE, beat time optimized axis motion PTP, and circular trajectory motion SCIRC, for example:
LINE V200
the segment of information shows that the motion mode is a straight line, and the motion speed is 200 x 0.001 m/s;
the control information mainly comprises instructions of gripper air suction/air release, bending machine pressing, turnover frame air suction/air supply and the like;
based on the information, the system robot bending simulation result can be subjected to motion track point interpretation and translation, and the control instruction of the bending robot in the actual processing environment is matched.
The present invention is not concerned with parts which are the same as or can be implemented using prior art techniques.

Claims (8)

1. The utility model provides a three-dimensional visual simulation of robot and off-line programming system towards panel beating is bent which characterized in that: it includes:
the equipment model library module is used for defining three-dimensional model file paths and key process parameters of each equipment required by the robot metal plate machining;
the equipment model selection positioning module is used for reading, matching and positioning a three-dimensional model of each piece of equipment required by the robot metal plate machining;
the sheet metal technology simulation module is used for reading sheet metal bending technology information and automatically calculating to construct a three-dimensional sheet metal model so that a sheet metal bending workpiece is bent and formed in a follow-up manner according to a bending planning procedure;
the bending system simulation module carries out overall operation path planning and visual simulation on the bending process of the robot through a bending control instruction generated based on metal plate bending process information, and is convenient for a user to check and verify the feasibility and the rationality of the bending operation of the robot;
and the bending robot operation program generation module is used for analyzing the bending simulation planning result and the bending robot operation path, and converting the bending simulation planning result into an instruction format of the bending robot to output.
2. The sheet metal bending-oriented robot three-dimensional visual simulation and off-line programming system as claimed in claim 1, which is characterized in that: the device model library module is established by the following steps:
the method comprises the following steps of firstly, carrying out three-dimensional modeling and local coordinate system definition on each device required by robot sheet metal machining based on SolidWorks and a CAD system, and storing the device in wrl file format, wherein the device comprises: the device comprises a bending machine tool, an upper bending die, a lower bending die, a sheet metal feeding and grabbing table, a sheet metal discharging and stacking table, a sheet metal centering table, a sheet metal turnover frame, joint elements of an industrial robot and a sheet metal gripper of the robot;
and step two, establishing a model database of each equipment according to the models, defining key process parameter data of each equipment, and using the database for rapid configuration of a selection scheme, function screening and model replacement of the robot automatic bending system in the equipment type selection process.
3. The sheet metal bending-oriented robot three-dimensional visual simulation and off-line programming system according to claim 1, characterized in that: the equipment model selection positioning module is established by the following steps:
step one, two initialization schemes are provided in the equipment model selection process:
the first scheme is as follows: a plurality of sets of general bending environment templates are equipped and stored in the system, and can be directly selected according to the type of the processed sheet metal workpiece and the key parameters of the model;
scheme II: manually selecting the type of the equipment and initially positioning the equipment according to the actual processing environment;
reading and displaying three-dimensional model files of all component equipment of the robot bending system by using an open source Coin3D three-dimensional graphical interface library;
and thirdly, setting relative coordinates of each component equipment model in a world coordinate system by taking a Cartesian coordinate system of the bending machine tool as the world coordinate system, positioning and correcting the components and element models of the bending system to form a bending system simulation environment consistent with the actual robot automatic bending system, and locally storing the model selection and position data information in an xml format file to reduce repeated model selection and positioning work of the equipment.
4. The sheet metal bending-oriented robot three-dimensional visual simulation and off-line programming system according to claim 1, wherein the sheet metal process simulation module is established through the following steps:
step one, obtaining the information of a metal plate bending workpiece to be simulated at present, comprising the following steps of: the method comprises the following steps of selecting a scheme of sheet metal workpiece material performance parameters, workpiece thickness, two-dimensional geometric information of each expansion surface of a workpiece, bending edge process information, sheet metal bending process information and a grabbing base surface;
step two, converting the bending information into a data format special for a cost system and storing the data format;
and step three, performing initial construction of the three-dimensional sheet metal workpiece in a simulation interface according to the data information in the step two, rotating base planes on two sides of the bending edge around the bending edge in the simulation process through the bending information provided by each bending procedure, and calculating the curved surface length of the bent edge after the inner side and the outer side are bent to perform three-dimensional entity construction so as to form a vivid workpiece bending simulation effect.
5. The sheet metal bending-oriented robot three-dimensional visual simulation and off-line programming system according to claim 4, characterized in that: the special data format for the bending workpiece information is characterized in that a center point of a captured base plane is used as a reference workpiece coordinate system of the sheet metal part, a bending edge sequence linked list based on bending processes is established, and each process data information comprises base planes on two sides of the bending edge, center coordinate information of the base planes relative to the reference coordinate system, a sheet metal bending edge bending angle and bending position data information.
6. The sheet metal bending-oriented robot three-dimensional visual simulation and off-line programming system according to claim 1, characterized in that the bending system simulation module is established by the following steps:
setting feeding and grabbing operations required in a simulation process of a bending system to determine an initial placing position and a grabbing and grabbing posture of a sheet metal workpiece to be simulated; the setting information comprises but is not limited to the translation position of the sheet metal workpiece coordinate system and the safety height of the gripper compared with the coordinate system of the feeding grabbing table;
setting the centering operation required in the simulation process of the bending system so as to simulate the secondary calibration and grabbing operation of the robot gripper on the bent sheet metal part in the actual machining process; the set information comprises but is not limited to the precise grabbing plane position and grabbing angle of the grabbing hand relative to the coordinate system of the sheet metal workpiece to be bent;
step three, performing path planning calculation on bending operations of each procedure required in the simulation process of the bending system, analyzing the position information of each bending required to move to the bending machine through the stored bending information of the bending workpiece, simulating actual bending work, calculating a safe position point outside a working area of the bending machine, a safe point entering the bending machine and a point to be bent, and performing dynamic simulation on a three-dimensional model of each bending operation process;
setting blanking stacking operation required in the simulation process of the bending system, and firstly automatically calculating a forming bounding box of the bent sheet metal workpiece in the system to determine the placing position and the gripping posture of the bent sheet metal workpiece; the setting information comprises but is not limited to the translation position and the placing height of the sheet metal workpiece coordinate system compared with the blanking stacking platform coordinate system;
and fifthly, replanning an operation path for a collision position possibly occurring in the simulation process of the bending system, inserting a new safe point pose and ensuring that no physical collision occurs in the simulation process.
7. The sheet metal bending-oriented robot three-dimensional visual simulation and off-line programming system according to claim 6, characterized in that: in the simulation process of the bending system, the bending operation of each procedure is calculated to simulate the actual processing process, and the method comprises the following steps: the automatic bending method comprises a feeding process of grabbing a workpiece by a robot gripper to a bending machine, a sheet metal bending forming process of pressing down a sliding block on the bending machine, a discharging process of driving the workpiece to move out of the bending machine by the robot gripper after bending is completed, and a sheet metal part turning process, a gripper replacing process and other robot automatic bending process processes according to a turning frame.
8. The sheet metal bending-oriented robot three-dimensional visual simulation and off-line programming system according to claim 1, characterized in that: the bending robot operation program generation module is a general bending robot operation instruction format designed for solving the problems of coordinate system definition and different instruction formats of different robots, and the information of the bending robot operation instruction format comprises: point location information, motion information, control information; firstly, all path nodes of robot operation in the simulation process are obtained by summarizing the simulation scheme of the bending process of the robot generated by the bending system simulation module, then all the path nodes of the robot bending simulation are converted into the pose of the robot end effector, and the pose is converted into the required bending robot operation instruction to be stored and output.
CN202110972440.3A 2021-08-24 2021-08-24 Three-dimensional visual simulation and off-line programming system of robot for metal plate bending Pending CN113681574A (en)

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Application publication date: 20211123