Partner:

3D s.r.o.

Challenge:

The intersection of flexibility for small batch production on the one hand and tooling complexity for mass production on the other is a gray area. A balance between investment costs and profitability can be leveraged with the added value of the used technology like machine vision.

The possibility to utilize the advanced function of CAD robot path generation on any curve, together with part localization algorithm in 3D space, opens new areas for technological applications such as arc welding, gluing, plasma cutting, and many more. This approach offers high flexibility and productivity even in small series production. 

3D s.r.o. combines offline programming and 3D machine vision to synchronize the robot’s trajectories with the actual part position and create precise 3D scans of the working area.

Solution:

PhoXi 3D Scanner

In this concrete application, 3D s.r.o. uses the PhoXi 3D Scanner from Photoneo for an arc welding application in harsh environments, which may include spatters and fumes, without any additional calibration with the robot. This enables them to move the scanner to a spatters-free position before welding. 

3D s.r.o. uses a medium-sized Photoneo PhoXi 3D Scanner to scan the working area of a collaborative robot. Afterwards, they analyze the 3D scan with their application. 

The result is a precise location of the parts to be welded. This information is sent to the robot to adjust its trajectories and weld the parts. 

Hardware used: 

Robot: collaborative robots Yaskawa HC10 Robotic Simulation, ABB GOFA CRB 15000 

Software: MotoSim EG-VRC 

Robotic Simulation Software: RobotStudio

Arc welding equipment: Binzel iROB Pulse 500

Machine vision: Photoneo PhoXi 3D Scanner model M

Discussion:

The deployed technology offers the following advantages:

• It is easy to start, with helpful and detailed documentation, including examples
• API interface for customized software
• Factory support
• Precise 3D scans of the working area with high resolution and minimum noise
• Reduction of costs for tooling and fixtures
• Possibility to prepare production offline in advance
• Increase in the overall equipment availability
• Reduction of the equipment downtime for setup and teaching 
• Flexibility in easy-to-change batch production
• Geometry inspection with alignment and comparison of CAD and scanned data

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