Efficient RoboDK Tools for the Virtual Commissioning of Flexible Robotic Cells

In today’s manufacturing industry, virtual models are widely used for machine and robot design to analyze behavior and optimize processes. However, there is a lack of unified methods and tools for simulating and virtually commissioning multi-brand robotic systems with distributed control in a single software environment. Coordinating PLCs (Programmable Logic Controllers) and robot controllers is crucial, especially as market demands push for shorter design cycles and faster time-to-market, requiring more efficient production processes. To address this, UNIMORE has developed a novel tool that enables co-simulation between RoboDK, dedicated to robot simulation and offline programming, and a PLC development platform like Beckhoff TwinCAT. Since these platforms don’t natively communicate, the tool facilitates data exchange, particularly the I/O signal values between the PLC program and virtual devices in RoboDK. This solution allows the design and commissioning phases to be conducted simultaneously, significantly reducing both time and costs. Additionally, it enables the PLC program to be optimized by testing different process sequences in the virtual environment. The tool was developed as part of the H2020 PeneloPe project (G.A. 958303, https://penelope-project.eu/) to perform offline tests of various process sequences and identify the optimal one for the specific use case. The initial demonstration involved replicating the robotic cell at UNIMORE’s lab within the RoboDK environment. The simulated process is the deburring of a cast iron carter, with key devices including a KUKA KR210 R2700 Prime robot, a tool warehouse, and a spindle. Once the 3D model was established, both the robot and PLC programs were written. These two programs, along with a Python-based interface, form the communication modules. RoboDK stores a list of all sub-programs the robot must execute during the production cycle. A main program waits for PLC input, triggering the appropriate sub-program. The Python interface, embedded in RoboDK, manages real-time communication, continuously updating I/O signals between RoboDK and TwinCAT. This setup allows engineers to simulate different process sequences, refine the PLC program, and optimize the entire system in a virtual setting. The next step involved applying this virtual commissioning tool to the Aerospace Pilot Line use case of the PeneloPe project. The technologies developed will be demonstrated at SAM|XL’s facility, using their gantry system. In this case, an enhanced version of the tool has been created, using ROS 2 as the system coordinator. In this setup, tasks and operations for each automated device modeled in RoboDK are managed through ROS. Asynchronous client-server communication is established between the two environments via the ROS rclpy library, allowing for effective task coordination. This version will be tested in SAM|XL’s facility to further validate its capabilities.

在当今的制造业中，虚拟模型被广泛应用于机器和机器人的设计，以分析行为和优化流程。然而，在单一软件环境中模拟和虚拟调试多品牌机器人系统，特别是具有分布式控制功能的系统，缺乏统一的方法和工具。协调可编程逻辑控制器（PLC）和机器人控制器至关重要，尤其是在市场需求推动设计周期缩短和上市时间加快的背景下，这要求生产过程更加高效。为此，UNIMORE 开发了一款新型工具，该工具能够实现 RoboDK（专注于机器人模拟和离线编程）与 PLC 开发平台（如 Beckhoff TwinCAT）之间的协同仿真。由于这些平台本身不具备原生通信能力，该工具促进了数据交换，特别是在 PLC 程序与 RoboDK 中的虚拟设备之间的 I/O 信号值交换。此方案允许设计和调试阶段同时进行，显著降低时间和成本。此外，它还使得 PLC 程序能够在虚拟环境中测试不同的工艺序列，从而进行优化。该工具作为 H2020 PeneloPe 项目（G.A. 958303，https://penelope-project.eu/）的一部分开发，用于执行各种工艺序列的离线测试，并确定特定用例的最佳方案。最初的演示涉及在 RoboDK 环境中复制 UNIMORE 实验室中的机器人单元。模拟的工艺是铸铁油箱的去毛刺，关键设备包括 KUKA KR210 R2700 Prime 机器人、工具库和主轴。一旦建立了 3D 模型，就编写了机器人和 PLC 程序。这两个程序以及基于 Python 的接口共同构成了通信模块。RoboDK 存储了机器人在生产周期中必须执行的所有子程序的列表。主程序等待 PLC 输入，触发适当的子程序。嵌入在 RoboDK 中的 Python 接口管理实时通信，持续更新 RoboDK 和 TwinCAT 之间的 I/O 信号。这种设置允许工程师在虚拟环境中模拟不同的工艺序列，细化 PLC 程序，并优化整个系统。下一步是将此虚拟调试工具应用于 PeneloPe 项目的航空航天试点线用例。开发的技术将在 SAM|XL 的设施中展示，使用他们的龙门系统。在这种情况下，创建了一个工具的增强版本，使用 ROS 2 作为系统协调器。在这个设置中，RoboDK 中建模的每个自动化设备的任务和操作都通过 ROS 管理。通过 ROS rclpy 库在这两个环境之间建立异步客户端-服务器通信，从而实现有效的任务协调。这个版本将在 SAM|XL 的设施中进行测试，以进一步验证其能力。