Model-based planning assistance for increasing the process accuracy in the robot-based, cutting pre-machining of large components (HoRuS²)

Photo of a large robot arm © Peter Winandy  


The process capability of an industrial robot (IR) for metal cutting has been investigated in the predecessor project HORuS with so-called stability maps. Compared to conventional machine tools (MT), IR have lower absolute accuracies in terms of system technology. Furthermore, static and and dynamic characteristics of serial robot systems are not comparable to those of MT. Investigations in HORuS showed that the robot-based pre-machining is possible with suitable process parameters. One approach to increase the process accuracy of robot-based machining of large components is the development and conceptual design of a model-supported CAM planning assistance.



The aim of the research project is to provide small and medium-sized companies with access to innovative alternative machining possibilities with IR. This includes the development of new methods and strategies for increasing process capability on an already existing prototypical demonstrator, which offers an optimal basis. The focus is on the development of integrative CAM planning modules that positively support the process planning process. With the help of the available demonstrator, the approaches developed for increasing the machining accuracy of an IR will be extensively validated and tested close to the industry. The demonstrator is thus intended to enable the participating research centers and companies to put the knowledge gained into practice.


Procedure of the first project phase

Workpiece measurement of small quantities on MT is often done manually with a tactile probe, which is clamped in the machining spindle like a tool. In the first phase of the project, it will be investigated whether precise part measurement using this method can be usefully employed with industrial robots due to their lower absolute accuracy but high repeatability. To this end, a method is being developed to calculate the zero point and orientation determination of workpieces using a robot-guided probe.