Brief description
This service aims to increase the efficiency of robot manipulators working with flexible parts, which is a particularly relevant task in the automotive and aerospace industries. Such parts behave unpredictably at high speeds: they may sway, bend, twist or become entangled due to inertia, gravity and air resistance. This reduces positioning accuracy, forces a slowdown in the cycle (as the robot has to wait for the oscillations to decay), creates a risk of impacts and damage to parts or equipment, and complicates the automation of assembly operations on the conveyor.
Benefits for the customer
High motion accuracy
Thanks to the precise modelling of the flexible object’s dynamics, the robot can predict the part’s position and move it while minimising oscillations. This restores the required positioning accuracy, even when manipulating flexible components.
Cycle acceleration
Advanced motion control algorithms (e.g. the Input Shaping method) actively dampen the flexible part’s oscillations. The robot does not need to pause or move slowly while waiting for stabilisation, reducing the cycle time.
Reduction of wear and damage
Controlled motion eliminates sharp, uncontrolled jerks of parts. This significantly reduces the risk of collisions with equipment and between parts, preventing breakages and extending tooling service life.
Automation of complex operations
The technology enables robots to reliably work with flexible components. Previously, assembly operations were considered too complex for automation due to the ‘capricious’ behaviour of flexible parts, but now robots can perform these operations at high speed and with high repeatability.
Optimisation of robotic operations
Role of the team
- Modelling of flexible objects: Mathematical models are developed to describe how a flexible part deforms and oscillates during motion by the robot. These models enable the prediction of behaviour, such as the amplitude and frequency of swaying, for different part shapes and materials.
- Damping algorithms: Intelligent motion control algorithms are created that can suppress oscillations. One such algorithm is the Input Shaping method, which involves a special correction of the robot’s trajectory whereby the part’s natural vibrations cancel each other out and decay rapidly.
- Feedback systems: Sensors and cameras are integrated to provide the robot with real-time feedback on the position and shape of the flexible part. For example, vision sensors (i.e. computer cameras) or force sensors on a gripper with vacuum suction cups enable the motion of the part to be tracked and the robot’s trajectory to be corrected instantly, thereby preventing swaying.
Implementation in practice
Specialists perform a dynamic analysis of the flexible part using the finite element method. Based on this analysis, a surrogate model is created that reproduces the part’s dynamic behaviour during robot-assisted manipulations in near real time. This type of modelling enables work with flexible objects to be incorporated into virtual commissioning systems and robot motion trajectories to be optimised to dampen oscillations and minimise production cycle time. Once the algorithms have been configured, test cycles are carried out in which the robot performs typical motions with the flexible object and the system damps the resulting oscillations in real time. Engineers then evaluate the results in terms of positioning accuracy, cycle time and the absence of impacts, and make fine adjustments to the parameters if necessary. The solution is then implemented in practice: the robotic system begins to manipulate flexible parts more efficiently, thereby increasing overall productivity and automation in the area.