<p>Projektet ProFlexA syftar till att automatisera gjutgodsrensning av stålgjutgods vid lågavolymer genom att använda ny adaptiv teknik såsom flexibla fixturer och gripdon samtkraftstyrning. Projektet bedrivs av Linköpings Tekniska Högskola och Lunds TekniskaHögskola med stöd av tre gjuterier i Mellansverige samt systemintegratörer och leverantörer.Automatisering av gjutgodsresning har länge varit föremål för både forskning ochkommersiellt intresse. Det finns idag fungerande lösningar främst riktat mot aluminiumgodsoch högre produktvolymer.Syftet med examensarbetet var att undersöka huruvida Robotstudio, och mer specifikt desstilläggsmodul Machining, var lämpligt för användning vid gjutgodsrensing. För att detta skallvara möjligt på hårdare material krävs kraftstyrning, vilket finns som tillval i den tidigarenämnda tilläggsmodulen.För att ha möjlighet att testa machiningmodulen och få en uppfattning om vad Robotstudio ärkapabelt till genomfördes först en självstudie av programmet. Som delmål för instuderingengenererades en visuell robotcell enligt ett av ProFlexA:s tidigare koncept förgjutgodsrensning. Denna process innefattade både den rent geometrihanterandeprogramdelen och den robotprogrammerande, vilken är den som senare kom att ha störstbetydelse under testerna. Därefter kopplades Robotstudio till befintligt robotstyrsystem ochde fysiska testerna planerades och förbereddes. Efter detta utfördes testerna för att undersökamachiningmodulens användarvänlighet och exakthet.</p><p><strong>Slutsatser</strong></p><p>• Robotstudio är lätthanterligt för en ny användare med tidigare erfarenhet inomrobotstyrning och RAPID-programmering.</p><p>• Generering av banor sker generellt med stor tidsvinst i machiningmodulen.</p><p>• Vidare tester med inriktning mot kraftstyrning borde utföras då möjlighet till dettafinns.</p> / <p>The project ProFlexA aims towards automating the cleaning of die-casted steel goods at lowvolumes by using new adaptive technology such as flexible fixtures and grippers and forcefeedback. The project is run by Linköpings Tekniska Högskola and Lunds TekniskaHögskola, with support from three foundries from the middle of Sweden together with systemintegrators and suppliers.Automation of the cleaning of die-casted goods has been a subject of both scientific andcommersial interest for a long time. There are working solutions today, but these are mostlyaimed towards aluminum goods and larger volumes.The purpose of this thesis was to examine if Robotstudio, and more specifically its add-inmodule Machining, was suitable for usage in the cleaning of die-cated goods. To make thispossible when using harder materials force feedback is required, which is possible to use inthis earlier mentioned module.To be able to test the machining module and get an understanding of what Robotstudio iscapable of, a self-study of the program was conducted. As a partial goal of the self-study avisual robot cell was generated according to one of ProFlexA:s earlier concepts for cleaningof die-casted goods. This process involved both the part of Robotstudio that handles thegeometry and the part that handles the robot programming, which is the one that was going tobe the most important during the tests later on. After this, Robotstudio was connected to theexisting robot system and the physical tests were planned and prepared. The tests were thenconducted to examine the user friendliness and exactness of the machining module.</p><p><strong>Conclusion</strong></p><p>• Robotstudio is easy to use for a new user with previous experience in robot controland RAPID programming.</p><p>• Generating robot paths in the machining module usually takes less time.</p><p>• Further tests aimed at force feedback should be conducted when possible.</p>

Projektet ProFlexA syftar till att automatisera gjutgodsrensning av stålgjutgods vid lågavolymer genom att använda ny adaptiv teknik såsom flexibla fixturer och gripdon samtkraftstyrning. Projektet bedrivs av Linköpings Tekniska Högskola och Lunds TekniskaHögskola med stöd av tre gjuterier i Mellansverige samt systemintegratörer och leverantörer.Automatisering av gjutgodsresning har länge varit föremål för både forskning ochkommersiellt intresse. Det finns idag fungerande lösningar främst riktat mot aluminiumgodsoch högre produktvolymer.Syftet med examensarbetet var att undersöka huruvida Robotstudio, och mer specifikt desstilläggsmodul Machining, var lämpligt för användning vid gjutgodsrensing. För att detta skallvara möjligt på hårdare material krävs kraftstyrning, vilket finns som tillval i den tidigarenämnda tilläggsmodulen.För att ha möjlighet att testa machiningmodulen och få en uppfattning om vad Robotstudio ärkapabelt till genomfördes först en självstudie av programmet. Som delmål för instuderingengenererades en visuell robotcell enligt ett av ProFlexA:s tidigare koncept förgjutgodsrensning. Denna process innefattade både den rent geometrihanterandeprogramdelen och den robotprogrammerande, vilken är den som senare kom att ha störstbetydelse under testerna. Därefter kopplades Robotstudio till befintligt robotstyrsystem ochde fysiska testerna planerades och förbereddes. Efter detta utfördes testerna för att undersökamachiningmodulens användarvänlighet och exakthet. Slutsatser • Robotstudio är lätthanterligt för en ny användare med tidigare erfarenhet inomrobotstyrning och RAPID-programmering. • Generering av banor sker generellt med stor tidsvinst i machiningmodulen. • Vidare tester med inriktning mot kraftstyrning borde utföras då möjlighet till dettafinns. / The project ProFlexA aims towards automating the cleaning of die-casted steel goods at lowvolumes by using new adaptive technology such as flexible fixtures and grippers and forcefeedback. The project is run by Linköpings Tekniska Högskola and Lunds TekniskaHögskola, with support from three foundries from the middle of Sweden together with systemintegrators and suppliers.Automation of the cleaning of die-casted goods has been a subject of both scientific andcommersial interest for a long time. There are working solutions today, but these are mostlyaimed towards aluminum goods and larger volumes.The purpose of this thesis was to examine if Robotstudio, and more specifically its add-inmodule Machining, was suitable for usage in the cleaning of die-cated goods. To make thispossible when using harder materials force feedback is required, which is possible to use inthis earlier mentioned module.To be able to test the machining module and get an understanding of what Robotstudio iscapable of, a self-study of the program was conducted. As a partial goal of the self-study avisual robot cell was generated according to one of ProFlexA:s earlier concepts for cleaningof die-casted goods. This process involved both the part of Robotstudio that handles thegeometry and the part that handles the robot programming, which is the one that was going tobe the most important during the tests later on. After this, Robotstudio was connected to theexisting robot system and the physical tests were planned and prepared. The tests were thenconducted to examine the user friendliness and exactness of the machining module. Conclusion • Robotstudio is easy to use for a new user with previous experience in robot controland RAPID programming. • Generating robot paths in the machining module usually takes less time. • Further tests aimed at force feedback should be conducted when possible.

Volvo is continually updating and replacing their equipment and want to investigate the possibility to shorten the time it takes to implement changes and shorten the time in commissioning projects. The use of an emulation model of a production cell can shorten the commissioning time since the equipment and sequence of the cell can be thoroughly tested before implementation. Volvo also wants to investigate the possibility to validate equipment using emulation. The main objectives are to find an emulation software that suits Volvo’s needs and build an emulation model of an actual production cell at Volvo called G750. A literature review was performed in which the authors gained knowledge about virtual commissioning, simulation and emulation and the usage of these. A market survey was conducted in order to find emulation software that could handle Volvo’s complex production equipment consisting of ABB robots and Siemens PLC. A method for building emulation models of existing production equipment was found during the literature review. The software used to build the emulation model was Simumatik3D. Other software used to make the model as realistic as possible includes RobotStudio, WinCC and PLCSIM. The emulation model handles approximately 350 inputs and outputs. When the emulation model was finished experiments were conducted in order to answer research questions and to reach the main objectives. The experiments validate that the emulation model is representative of the real production cell regarding programming, fail scenarios and movement.

Undersökningar och beräkningar av en rengöringsprocess med ibc-containers vid Allemballage har gjorts. En automatiserad lösning har tagits fram där vissa delar har tillhandahållits i förväg som rengöringsverktyg. Uppgiften blev att studera om verktyget klarade av de räckvidder som var avgörande samt att fastsälla om den robot som kunden ville använda sig av kunde utföra uppgiften genom att ta reda på vilket moment som uppstod för att sedan ta fram en simulering av processen i RS. Räckvidden undersöktes dels i RS men även ett presentationsunderlag togs fram. Momentet undersöktes dels praktiskt där man fastställde de krafter som verkade och teoretiskt där man sedan beräknade momentet. Det sista som gjordes var en simulering på hur processen kan se ut då en IRB4600-robot ifrån Abb och rengöringsverktyg utförde en rekonditionering av en IBC. Resultaten har visat att momentet i kortare stunder överstiger det krav som ställs på önskad robot men att verktyget klarar de räckvidder som ställs. Räckvidden och momentet har visat sig vara beroende av varandra då en minskning av räckvidden leder till ett mindre moment, vise versa. Med de undersökningar som gjorts och det resultat som tagits fram är rekommendationen i dagsläget att man bör lägga en beställning på det aktuella rengöringsverktyget. Vidare så anses robot IRB4600 kunna utföra uppgiften som tänkt, mindre justeringar bör då göras vid de ställen som visat sig utgöra det största momentet vid rengöring.

The diploma thesis deals with the virtual commissioning of robotized workplace for cold spraying. The theoretical part of the thesis contains an overview of the current state of knowledge in the field of virtual commissioning, the theory of crating HMI user environments, deals principles of the Rapid programming language as a tool for controlling industrial robots and analysis of robotic workplace components. The practical part defines the structure of the proposed user program and user environment, which are created using software tools Robotstudio and Screenmaker. The last part discusses in detail the steps during the implementation of the created program together with the HMI into commission, which is associated with the testing of functionalities on a real device for cold spraying. The diploma thesis also includes a user manual created for operating an industrial robot.

The dynamic changes in the manufacturing sector have increased the competition between the industries. To sustain these disruptive changes and maintain competitiveness in the global market, companies need to continually improve their production performance, successfully developing and implementing innovative production practices, and producing high-quality products in shorter lead times at optimum costs. The variations and fluctuations in customer demands can be satisfied by introducing new technologies into manufacturing systems, which brings in varying flexibility and agility character into production. Introduction of robots in manufacturing system have increased the productivity and quality of the processes. Effective and efficient programming helps achieve flexibility in the production process because the robot programming aids the robot to perform various tasks and motion. ABB RobotStudio is one type of offline programming and simulation software that helps in stimulating the robot using a Virtual Robot controller. The simulation tool lets users recreate the production environment and program a robot and calculate the cycle time without a real robot.   This case study's objective is used to evaluate the aspect of simulation to be integrated into the case company's production development process and the use of simulation in optimizing the robot cell. Therefore, a case study was conducted at LEAX Group AB, a manufacturing industry. ABB RobotStudio was a tool used in this case study to simulate the existing production system.    The empirical findings have shown the mapping of flow and process mapping of the robot cell in LEAX Group. The empirical part highlights the building of the existing simulation model of the robot cell. The challenges faced while simulating the model are also discussed. The analysis part highlights the optimization of the robot cell and the integration of the simulation model into the production development process. Finally, a conclusion has been drawn by answering two research questions, and a recommendation is given. The conclusion highlights the integration of simulation in the production development process and the process of optimizing the robot cell.

This diploma thesis deals with digital commissioning of a robotic production system for laser cutting. First part of this thesis sums up teoretical knowledge of virtual commissioning, fundamentals of laser and laser cutting and system analysis of such a workplace. In practical part of this thesis, the workplace was designed including the workpiece clamping. The design and the digital commissioning itself was mediated by the software RobotStudio. In the programming language RAPID a control program was made and tuned. The workoplace was then virtually commissioned. For easier handling a user interface on FlexPendant was made.

Tese de mestrado integrado. Engenharia Mecânica. Universidade do Porto. Faculdade de Engenharia. 2011

The purpose of this bachelor thesis was to evaluate and propose a solution for how the material handling of steel rods produced by a metal cutting machine could be automated. The intention of the automation was to meet an increasing demand and to ensure that the quality requirements set are met. These quality requirements are defined by a removal of the small steel edge which occurs on the rod after the cutting process, as well as making sure that the rods meet the specified length tolerances. Initially, a data collection and status analysis of the process was carried out, where problem areas were identified and a requirements specification was formulated. Based on these findings, several solution proposals were generated. The proposed solutions were evaluated and used as a basis on which further development of automation solutions were conducted. During this development, a software simulation environment was used to simulate and evaluate the resulting concepts. Included with these concepts were drawings of necessary constructed equipment, simulation models and cost estimates. The work resulted in two concepts based on the use of industrial robotics. The concept that was considered most suitable for the task is based on an implementation of an ABB IRB 1600 industrial robot with a magnetic gripping tool, a stand-alone station for removing remaining steel edges from the rod, and a measuring arrangement to make sure that the tolerance requirements are met. / Detta examensarbete utfördes med syftet att undersöka om och hur materialhanteringen vid en kallsåg för stålstänger kunde automatiseras. Detta för att hantera en ökad efterfråga och säkerställa att de kvalitetskrav som ställs blir uppfyllda. Kvalitetskrav avser här att kvarvarande grader som uppstår på stängerna vid kapning ska vara borttagna och att stängerna ska uppfylla specificerade längdtoleranser. I arbetet genomfördes inledningsvis en datainsamling och nulägesanalys av processen där problemområden identifierades och en kravspecifikation formulerades. Utifrån dessa genererades sedan flera lösningsförslag. De framställda lösningsförslagen utvärderades och utgjorde sedan en grund för vidareutveckling av automationslösningar. Under vidareutvecklingen användes en robot simuleringsmjukvara för att simulera och utvärdera koncept. Till dessa koncept framställdes tillhörande konstruktioner, simuleringsmodeller och kostnadsuppskattningar. Arbetet resulterade i två koncept för automation baserade på ett användande av industrirobotar. Det koncept som bedömdes som mest lämpat för uppgiften bygger på en implementering av en ABB IRB 1600 industrirobot med ett magnetiskt gripverktyg, en fristående station för avgradning av stänger samt en mätanordning för att kontrollera att toleranskrav uppfylls.

The cab assembly line in Oskarshamn is one of the world's most high tech production unit. With close to 300 robots the cab is assembled with merely programmed robots and no input from humans. Scania CV AB is a world leading manufacturer of trucks with high influence on the market globally. Even though robots do most of the work, there have been human brains behind the robot execution, and there is constant work ongoing to further increase efficiency and cycle times to meet the increasing global demand for logistics services. The robots are mainly programmed offline, using the ABB software Robotstudio, which basically creates a digital representation of the actual control system without interfering with the production. Testing upgraded programs as well as simulating them offline before implementation is an essential daily operation to make the production meet the demands. This thesis is divided into two objectives, one theoretical and one practical. The theoretical part focuses on the software, and consists of a critical analysis of a series of different software solutions for programming robots offline, as well as a look into how the offline programming processes work today in-house. The practical objective is to further improve the quality of the simulations conducted through creating tools to answer the calls from functional packages for the different processing equipment used on site. These functional packages lets you perform spot welding, gluing or gripping for instance, and as it is an outsourced service a lot of the coding is encrypted which prevents simulations being conducted with the pre-programmed routines, it makes the simulations crash. This report presents conclusions made regarding the use of offline programming equipment both in the regards of daily operations as well as long term strategies with digital twins and digitization. It also proves that the functional packages still can be simulated even though the code has been manipulated and encrypted at one point. It holds the complete ways of how to, from a 3D CAD model, create mechanisms, synchronize external axes, and creating smart components to answer digital inputs and presenting digital outputs to the system to have a fully functional simulation run.