The future of industrial robots lies in virtual training camps

Robot Offline Programming (OLP) is not a new concept, but is becoming increasingly important in view of the growing demands in manufacturing. The reason: shorter product cycles, complex tasks and collaborative robot systems require flexible, high-performance solutions. In virtual environments, manufacturing companies can realistically simulate and optimize even complex movements. In this way, new processes and adjustments can be implemented with shorter set-up times and greater precision - without downtime on the system. 

At the same time, Robotics OLP lays the foundation for future technologies such as model-based engineering (MBE), in which digital product and process models are even more closely interlinked. But even today, the method is already making a difference. The Finnish company Visual Components, a pioneer in 3D production simulation, shows three areas in which the advantages are particularly clear:

1. Welding - precise tracks of the highest quality
   Welding work is one of the most demanding and at the same time most important fields of application for offline programming of robots - from arc and laser welding to spot welding and other processes. Precisely planned movement patterns allow complex welding seams to be simulated with millimetre precision, optimized and then reliably executed - without any intervention in ongoing operations. With the right simulation software, OLP ensures reproducible quality, reduces rework and enables automated production even for complex components. This not only increases efficiency, but also flexibility in production. 
2. Surface processing and cutting - more control with high complexity
   Grinding, blasting, polishing, deburring or cutting: These processes require exact trajectories and consistent material removal - requirements that comprehensive OLP software with CAD-based accuracy can fulfill. While manual programming is not only time-consuming and difficult to reproduce, offline programming in the virtual environment can also process and optimize complex geometries in advance before the first chip falls on the production floor. This enables manufacturing companies to adjust angles, pressure and movements in such a way that repeatable, high-quality results are guaranteed for every part.
3. Painting processes - simulation instead of surprise
   When it comes to robot-assisted painting, OLP really comes into its own in the preliminary stages: Digital simulation allows the paint application to be planned in detail - including layer thickness, spray angle and distance. This not only improves the surface quality, but also minimizes material consumption and rework. In addition, painting robots can be adjusted more quickly to new component geometries or color variants - a real booster for flexibility.

"Robot Offline Programming is a central key to flexibility in production today," says Jarkko Siltamäki, Business Development Director, Robotics at Visual Components. "In view of ever shorter product cycles and changing customer requirements, robot-independent OLP solutions are essential for virtually simulating, optimizing and adapting processes - without disrupting real production. The production line in particular shows how quickly technology and the market are changing today."

Source and further information: Visual Components