Robotic simulation streamlines painting operations

The Delmia Igrip robotic solution and UltraPaint have been implemented at the Caterpillar facility in Decatur, Illinois to assist in the upgrade of the company's robotic paint production lines.

The Delmia Igrip robotic solution and UltraPaint have been implemented at the Caterpillar facility in Decatur, Illinois to assist in the upgrade of the company's robotic paint production lines where a number of new robots have been installed requiring intensive reprogramming.

In order to deliver the project in a timely manner, it was agreed by all parties that utilising the Delmia Igrip software with the UltraPaint add-on was the optimal solution.

Igrip is a physics-based, scalable robotic simulation solution for quick and graphical modelling and offline programming (OLP) of complex, multidevice robotic workcells for applications such as painting, welding, dispensing, material removal and machine tending.

The OLP capability allows users to accurately program robotic systems without tying up physical resources on the factory floor thereby reducing man-hours and process engineering lead-time while improving accuracy.

Included with the UltraPaint is a complete set of painting simulation tools.

Spray gun and paint attributes can be entered into the painting device and the results can be graphically displayed in multiple colours illustrating relative film thickness; or exact thickness can be obtained though the uses of a built-in film build gauge.

Complex paint booths can be constructed, and multiple robot moving line applications can be simulated.

Additionally, the Realistic Robotic Simulation (RSS) feature allows the Igrip software to interface with a robot manufacturer's proprietary motion planning software (called an RCS module) to provide greater accuracy in the trajectory motion and cycle time prediction.

The Delmia Igrip calibration tools let users adjust the simulation model to accurately reflect real world device relationships, while the signature interface enables programmers to easily modify robot devices to gain accurate robot motion.

Finally, users download the optimised simulation programs using Igrip's postprocessors.

In this application, each existing part paint program was simulated in the cell, taking into the consideration the new robots in order to check for reach ability and clearances.

With the simulation capability, existing programs could be optimised to gain efficiencies.

For example, any unnecessary helicopter moves where the wrist wraps around in a 360-degree move and is typically a waste of motion and time were able to be identified and eliminated.

Igrip is part of the Delmia Resource Modelling and Simulation solution suite, providing the tools to develop and implement resources, application routines and mechanical programming.

Within this set of solutions, resources such as robots, tooling, fixtures, machinery, automation and ergonomics are defined and infused into a complete manufacturing scenario.

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