Accuracy optimization of highly dynamic, robot-based manufacturing processes through model-based simulation and compensation

  Representation of the different phases of robot control © Lukas Gründel  


The aim of this project is to develop an approach in order to increase the process capability of the production tool "robot" for highly dynamic machining processes, for example high-speed cutting, laser cutting and additive manufacturing processes. The machining task and, consequently, the production program or the production paths of the robot are of great importance. In addition, process forces can occur that displace the end effector of the robot. Simulation and compensation of the various process influences is therefore necessary to ensure stable machining during production planning by optimizing the process parameters. In the preceding project HoRuS², a considerable improvement of the final contour for a machine cutting pre-process was possible with the help of a model-based compensation.



In order to ensure transferability to any industrial robot for dynamic processes, the RoSiKo project is striving for a data-driven identification of the dynamics model. Further areas of focus are the provision and use of the identified robot model. Model-based assistance tools within a simulation environment support the manufacturing planner. The simulation assistance provides the planner with process knowledge and optimization methods as well as predictions about the machining result. Since optimizations in the work preparation cannot eliminate all mentioned manufacturing deficits, a compensation strategy is developed as well. The compensation uses the developed model to compensate for the predicted deviations from the nominal contour. During the development of the solution approach, special attention lies on the transferability to the heterogeneous industrial control landscape. For project validation, the demonstrators HoRuS² and AuRoNa3D will be used. The project is further controlled by the project accompanying committee, which consists of project partners in the industry. The committee advises on current practical issues, transfer and practical implementation of the results.