In a recent collaborative effort with FORCE Technology and Hexagon Manufacturing Intelligence using ESPRIT additive toolpath programming, an industrial robot was programmed using RoboDK’s simulation software. ESPRIT and RoboDK, a powerful combination of toolpath programming and robot digital twin with post-processing and analysis capabilities, were used to create the final part.
The system included a 6-axis KUKA robot arm mounted on a rail (linear axis), a tilting table for rotary operation, and a spindle. Additionally, a GTV cladding head (powder+laser) enabled additive functions resulting in an overall cycle time of 5 minutes when reloading Steel 4140 parts. This project examined the numerical chain within FORCE Technology‘s setup through a genuine application instance.
RoboDK enables customers to be less wasteful
Ever mindful of their environmental responsibilities, the project enabled FORCE Technology to determine how to repair a gear instead of replacing it.
In turn, they avoided throwing away a whole part and wasting materials and labor costs. In addition, they kept downtime and costs low due to eliminating the need for replacement parts. The project was a successful example of how robot integration can improve MRO (Maintenance Repair and Operations) to alleviate sustainability concerns.
FORCE Technology employed ESPRIT, the Hexagon’s “Hybrid” CAM to program additive head path planning, and RoboDK to resolve kinematics and collisions while generating robot code to create the toolpath trajectories for Additive Manufacturing.
In addition, the RoboDK extension in ESPRIT simplified communication between systems and made it easier for end-users. Overall, FORCE Technology completed the MRO application using digital twin and post-processing to improve weld quality and waste reduction. The Manufacturing Academy Denmark (MADE) provided the financial backing to make this project successful.
How robotic simulation with RoboDK can help alleviate sustainability concerns
Companies can reduce their carbon footprint by repairing large components with defects or damage compared to manufacturing a complete new part.
“The project was a big step stone towards making gear repair more standard and achieving the required guarantee of quality and confidence to put repaired gears back into service from the gear manufacturers. We successfully achieved the identical hardness of the original teeth on the gear as printed,” said Ivar Dale, additive manufacturing specialist at FORCE Technology.
RoboDK’s simulation and offline programming tools can also reduce production downtime caused by shop floor programming. Companies can test a robot’s abilities in a virtual environment with RoboDK.
“Using the path planner additive solution from ESPRIT/Hexagon, and the post-processor from RoboDK we saved a tremendous amount of time to program the path with a 1mm positive offset as the shape of the tooth was organic,” Dale added. “This saves us time in printing, especially in larger repairs, but it also saves the gear manufacturer time as the material we add is very hard and every mm takes time to carefully CNC.”
Improve your laser welding initiatives with RoboDK industrial simulator
RoboDK eliminates the need for shop floor programming and optimizes robot paths to avoid singularities, axis limits, and collisions. Due to its innovative design, coding experience isn’t necessary.
By combining RoboDK with another system, such as the ESPRIT, Hexagon’s “Hybrid” CAM, companies can develop sustainable production processes. It reduces energy consumption and waste generated from their operations.
Using RoboDK’s simulation and offline programming tools helps companies reduce production costs and downtime. Moreover, it minimizes hazardous materials produced in production cycles.
These advantages make RoboDK an invaluable tool for companies looking to reduce their environmental impact. In addition, if your business is committed to sustainability, then RoboDK can help you achieve your goals.
Combining RoboDK with other software solutions allows businesses to develop sustainable production processes. This will help ensure that the company is committed to tackling sustainability concerns and can be confident that its production processes align with the latest industry standards.
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