Easy preparation of robot programmes and kiln car settings with KELLER HCW’s K-matic Visual Robotics Software
[February 2011] KELLER HCW has developed new software to prepare robot programmes without needing any programming knowledge.
Nowadays, robots in brickworks fulfil a large variety of functions. These may all work perfectly but for each new brick format it is necessary to create new robot programmes. The easy creation of the programmes combined with a realistic 3D display of kiln car settings are the assets of this new software. A simulation display shows how the bricks will be set on the kiln car. This simulated process can then be implemented into the operating panel to give a graphic display of the robot cycles.
1. Basic features
1.1 Which components are required?
Provided that robot and PLC control system are already there, an additional 19" touch screen operating panel and a computer with the K-matic Visual Robotics Software is needed. A network cable connects the computer with the robot, the PLC and the operating panel.
1.2 Where is the system used?
It is a multiple-use programme. It was laid out for a kiln car setting installation with robots. Other application sites, such as unloading, packaging, wet and dry sides can be implemented without any problem. It is possible to control smaller setting installations with only one robot as well as larger ones working with several robots.
1.3 How much time does it take to make format changes?
The programme is used in two phases, the planning phase and the implementation phase. At first the kiln car setting is created on a desktop PC with a large 24" 16/9 monitor. During implementation, the programme can also be accessed from the operating panel to configure final settings. In other words, the robot programmes can be modified on the operating panel as easy as any other settings.
2. Function
2.1 Creation of new kiln car settings
The standard procedure is to take an existing setting, to copy it and to adapt it to the new requirements, but it is also possible to create a complete new kiln car setting. Similar to a CAD programme, the first step is to create a brick. Height, length, width and the surface characteristics are entered. The second step is to determine the brick load the robot has to take up. This is a key function of the programme. The brick loads can be individually composed. Finally, the kiln car setting is developed from the brick loads for the robot and the sequence how the robot sets the brick loads on the kiln car.
2.2 Simulation test of the kiln car setting
When the kiln car setting is completed, the programme can run in simulation mode to test all its functions. Are all distances adequate? Is the sequence of the robot cycles correct?
When pressing the simulation button, the robot brick loads appear on the kiln car setting in green or red one by one in a one second cycle either in green or red colour. When all brick loads are green, the process is working correctly. When a brick load is red, a window opens and gives a detailed error description. The software recognises errors due to overlapping bricks and thus prevents the robot from depositing the upper brick layers too low on the bricks in the bottom layers.
2.3 3D pictures of the robot cycles for the operating panel (Picture 6)
Without pictures of the robot cycles on the operating panel monitor, only a very experienced user is able to predict where the robot will place the next brick load. Often only the cycle number is shown on the operating panel; such a display is hardly ever clear or even easy to understand. With the pictures of the robot cycles it is now easy to reconstruct what the robot has so far done and what will be its next step.
Picture 6 shows that the green loads are the loads that have already been set on the kiln car, the light green load is currently being set, and the brown loads are not yet set. If bricks in a robot load are damaged and fall from the gripper, it is immediately visible where bricks have to be exchanged. It is only necessary to press a button on the operating interface to create the cycle pictures, which are then displayed on the operating panel.
2.4 Implementation of new robot programmes
The software is very clearly arranged, which makes the implementation of new robot programmes a really easy task. With a mouse click on the green transfer button, robot data a transferred to the control system. Simultaneously, the PLC control programme transmits the number of the brick format and stores all transferred format numbers when more than one brick formats are created or modified in succession. The PLC gives a warning signal at the operating panel when new formats are selected. The robot speed is reduced to a very low implementation speed, which the user can increase, if required. Formats currently being produced on the installation are only transferred after the installation has stopped. The operator has to switch off the automatic mode for this purpose. Special care has been taken to integrate as many safety features into the software as possible. When, during the implementation, it will be necessary to shift loads slightly, the programme is opened on the operating panel (picture 3) and the values are modified there. Then the save button is pressed, initiating the transfer to the PLC. The automatic mode of the installation can now be restarted. With this procedure, it is possible to continue changing the formats as many times as needed until the required result is reached. Changes can also be made from the office desk, as the operating panel and the desktop PC in the office have access to the same data. Remote maintenance over the internet is also no problem at all.
2.5 Restoring data
When the operator has changed formats at the robot itself, these data can also be transferred backwards from the robot to the computer. With this feature, the programme proves that it offers very practicable solutions. "After the first tests in our robot test cell, we additionally installed some features that were requested by our customers. This included also a back transfer of data from the robot to the computer", informs the R&D department.
3. All robots can be controlled with this software
Though the system was mainly developed for setting and unloading installations, the developers of KELLER HCW did not make a secret of the fact that this system may also be used for all other robots in a brick factory, which can then be programmed with one simple user interface. It is a further asset that only one computer with the K-matic Visual Robotic Software is needed to provide all the robots in the factory with new brick formats. When new brick formats are implemented, the operating panels related to the robots all have access to the computer where this software is installed. And, incidentally, the central data storage considerably increases data security within the factory.
4. Summary
With its K-matic Visual Robotics software, KELLER HCW succeeded in making the complex robot technology so simple that everyone can create and modify new robot programmes. Moreover, operating robot plants with the new 3D cycle pictures on the operating panel seems like child’s play.
All in all, KELLER HCW GmbH managed to make a large step towards future horizons, where brick formats are planned, controlled and operated in three dimensional virtual spaces.
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