Grant agreement no.: 258769 European Press Conference, 7 th June 2011 -1- SIR and COMET Project: an Opportunity to Open New Horizons in Robot Manufacturing.

Grant agreement

no.: 258769

European Press Conference, 7th June 2011 -1-

SIR and COMET Project:an Opportunity to Open

New Horizons in Robot Manufacturing

Davide Passoni

Grant agreement

no.: 258769

European Press Conference, 7th June 2011 -2-

Agenda

Who I amSIR S.p.A.The Market of Robot Manufacturing COMET Objectives = SIR NeedsCOMET and SIR’s TechnologyThe Role of SIR in CometWhat We Are Doing and What We Will DoThe Delcam Software: the Added ValueThe Importance of Being Involved in EC Funded ProjectsConclusions

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Who I am

Computer Engineer (graduated in 1997, University of Modena and Reggio Emilia)

Employed in SIR from 1997, initially as robot programmer

Actually R&D Manager in SIR spaMember of SIR’s Board of Director

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no.: 258769

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SIR is part of the SITI – B&T Group S.p.A., the world’s second largest supplier of ceramic tile automation systems and plants: a work-force of more than 800 people in various locations world-wide, 450 of them in Italy.

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SIR Soluzioni Industriali Robotizzate S.p.A.

SIR is a robotic SYSTEM INTEGRATOR that satisfies all specific needs with the most suitable solution in any manufacturing sector and operates on the market as a real PROBLEM SOLVER.

automotive plastics foundry ceramics and bricksaeronautics logistics pharmaceuticals food & beverage

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no.: 258769

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SIR Soluzioni Industriali Robotizzate S.p.A.

• Constantly growing turnover

• 80% covered by orders from Italy and 20% from abroad

• From about ten employees • up to the 90 of today

• More than 2500 plants in operation world-wide

SECTORS OF APPLICATION 2009

Hot Forging6%

Die Casting10%

Deburring16%

Other proces/Assembling

10%

Machine Tending45%

Palletizing/Handling

13%

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The Market of Robot Manufacturing

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1990 1993 1996 2000 2003 2006 2008 2010

Shell MoldingDieCasting

Sand Casting

Manufacturing/Machining# Robots

Fonti: ABB.

Manufacturing and machining operations using robots will be the

next ”big thing” in foundry industries.

Expectations: +10% every year until 2014!

• Manufacturing and machining operations with robots are a core business for SIR (hundreds of installations worldwide).

• The request for “robofacturing” applications has been strong in the last 2 years (despite the very high contraction in automation market).

• The Robot Market in manufacturing and machining will be very high also in the next years, not due to growth of productivity, but to increasing request of high and constant quality.

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no.: 258769

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COMET Objectives = SIR Needs

• Deepening SIR knowledge on robotic manufacturing (ROBOFACTURING)

• Extending Industrial Robot field of application to high quality machining

– Improved dynamics– Higher precision– Higher reliability and flexibility– Higher productivity

• Enhancing SIR market opportunities (automotive, aeronautics and more)

• Fulfilling SIR’s customers request of HIGHER QUALITY ROBOTIC CELLS

COMET objectives and SIR needs are the same!

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no.: 258769

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COMET and SIR’s Technology

• Machine vision: the sensorial tool for interaction between the robot and its environment

• Robot guidance in 2D and 3D environments• Inspection of surfaces and dimensions and checking the correct assembly

• EasyPath (patented) real-time profile tracking and robot path generation

• Advanced 3D BIN PICKING

COMET resulting technology will be a great added value to SIR’s existing skills

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COMET and SIR’s Technology

• Virtual simulation: programming becomes learning, using Delcam software

• 3D display of operation of the robotic systems

• Generation of robot programs with time savings of 80% compared to traditional techniques

Simulation and Integrated DesignIn partnership with University of Modena and Reggio Emilia, Department of Mechanical and Civil Engineering

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COMET and SIR’s Technology

• Robots equipped with innovative multidirectional compensation systems

• High, reproducible machining quality

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European Press Conference, 7th June 2011

COMET and SIR’s Technology

• Machine vision and 3D programming• Robotics become adaptive: machines adapt to variations in the

environment and interact with the space around them• New centralised, modular machining units. The concept of

robofacturing is born: the product is designed for production using an automatic plant

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The Role of SIR in COMET

SIR Lay-out #1PSIR configuration

SIR Lay-out #2ATIR configuration

SIR Lay-out #3HDCM configuration

• Test and development of robot offline programming and advanced simulation based on Delcam software (WP2)

• Development of machining strategies and parameters (WP2)

• Validate the COMET approach, realizing and testing a machining robotic cell, with 3 modular and progressive lay-outs (WP4): PSIR configuration (offline programming) ATIR configuration (robot tracking) HDCM configuration (compensation mechanism)

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What We Are DoingPSIR Configuration already operating in SIRRobot offline programming and advanced simulation based on Delcam softwareWriting of SIR logo on aluminium block (firs system test)

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What We Are DoingStudying and development of machining strategies and parameters using DOE methodUnderstanding of robot accuracy using DOETest of offline programming and advanced simulation based on Delcam software using DOE

FeatureAnalysis

Surface Finishing Trajectory Errors Edge irregularities

Pockets D C C

Circular path CCC CC (C for junctions) C

Holes C C C

Straight path B B C

NPP (-1) MST (-1) RCO (-1)

HIGH Num points

WGP (1) TGP (-1) VEL (1)

3,6

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What We Will DoATIR configuration

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What We Will DoHDCM configuration (final machining cell!)

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The Delcam Software: the Added Value

Added Values:• Easy and accurate robot offline

programming and simulation

• Accurate and real dynamic and kinematic robot models

• Great experience coming from a long history in the world of CAD/CAM machining

• Integration with machining strategies and procedures

• Possibility to use it for every kind of 6-axis robot.

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The Importance of Being Involved in EC projects

R&D Added Values:Deepening SIR knowledge on robotic manufacturing (ROBOFACTURING) and on “state

of the art” technologies Collaboration with European Universities

Networking Added Values:• Create an European networking in robotic manufacturing• Create a collaboration between companies and univesities that will be useful also

after the end of the project

Market Added Values:• Enhancing SIR market opportunities (automotive, aeronautics and more)• Create a product that will be a core business for the company

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Conclusions

At the end:We will be able to design a NEW GENERATION of HIGH QUALITY MACHINING ROBOTICS

WORKCELLS…

…with human sensibility and flexibility…

…and with machine tools accuracy!

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Thank you for your kind attention