Author Topic: kuka PRC for parametric Laser Cladding  (Read 171 times)

sialam

  • Robots in Architecture Members
  • Forum User
  • *
  • Posts: 5
    • View Profile
kuka PRC for parametric Laser Cladding
« on: October 30, 2020, 06:05:42 PM »
Hello everyone.
My name is Syed and I am a student at University of Alberta, I am working in the automation of a laser cladding facility along with another fellow in the university. As for our setup we have a Laserline 9kw laser,  a Thermach powder feeder, a siemens PLC, a Kuka kr16 and a dkp400, in terms of software we decided to use Kuka prc as we believe it truly potentializes the  flexibility and ease of programming for multiple and complex geometries of our worn out parts that we are working in repairing.

So our workflow involves a 3D scanner that we use to create our model of the worn out part and then we use the 3D model in rhino in order to create the toolpath adding polylines. Once we do this, the laser and powders are controlled with the I/Os of the Beckhoff module and the siemens PLC.

Any how we are now struggling when we try to use our DKP and maintaining the tool as statically as possible and let the dkp do the most of the work in terms of moving. We are aiming at rebuilding a pipe as a test but for now we are using a plate.

My specific question is what type of values does the external axis accepts, angles? vectors? I tried to find this on the documentation but probably I missed it and just can't figure out and understand how should I input the values and also understand what I am inputting.

Finally I want to thank Karl and Johannes, your work is amazing and we are using most of the resources to put this together. My colleague Daniel reached Karl I believe but we didn't wanted to share anything until we had something much more useful or specific. So now We are showing our work here in order to share, hoping to get a bit of help as well as show the capabilities of in engineering processes. We will be featured in WELD magazine soon talking about our setup and the use of parametric programming and we are very happy to share this with you and hope to get more thing and collaborations in the future.

Thanks in advance  for everything and hope you find this interesting.


Johannes @ Robots in Architecture

  • Lead Developer
  • Administrator
  • Forum User
  • *****
  • Posts: 1074
    • View Profile
    • Robots in Architecture
Re: kuka PRC for parametric Laser Cladding
« Reply #1 on: November 02, 2020, 07:48:58 AM »
Hello Syed,

The external axis uses simple degrees as the input value, in the case of the DKP you have got one axis that sets the tilt and one that sets the rotation. Which one is E1 and which one is E2 depends on your particular setup and can be changed in the simulation (to fit your physical setup!) by right-clicking the DKP 400 component.
You can of course calculate the value so that e.g. the tool stays as vertical as possible, that code may be useful as a pointer, through it only uses one rotational axis:
https://forum.robotsinarchitecture.org/index.php/topic,822.0.html
Give it a try and if you get stuck somewhere, let me know - and clearly define what movement you want to delegate to the DKP, "most work" is too vague, do you want to keep the tool vertical? Keep the robot very close for stability?

Best,
Johannes

sialam

  • Robots in Architecture Members
  • Forum User
  • *
  • Posts: 5
    • View Profile
Re: kuka PRC for parametric Laser Cladding
« Reply #2 on: November 04, 2020, 08:23:19 PM »
Hi Johannes
Thanks so much for the reply, sorry if my description is not accurate.

What I mean is I want the e1 to maintain a 90 degree angle always and then the e2 to continuously rotate if necessary according to the toolpath, i.e. if I put a pipe in our chuck, I want e2 to rotate continuously and the tool maintain its position and just move a bit further to the end of the piece after every iteration.

I just downloaded the code that you pointed to me I will study the case and try again and let you know how are we doing. Thanks for the assistance.

We are working on a demo incorporating the Inconel powders and the laser so we might have a video of this to share with all of you guys. Also the Weld magazine should be out soon, I'll post the link for anyone to have a look at what we wrote, feedbacks, comments and anything is very well appreciated.

Johannes, Thanks again and I'll be in touch with you.

Syed


Johannes @ Robots in Architecture

  • Lead Developer
  • Administrator
  • Forum User
  • *****
  • Posts: 1074
    • View Profile
    • Robots in Architecture
Re: kuka PRC for parametric Laser Cladding
« Reply #3 on: November 05, 2020, 09:00:11 AM »
Hello Syed,

I think the linked code should work well for that, please give it a try and if it doesn't work as expected let me know and I'll look at it in detail, OK?
And it would be great if you could post a link to the article you mentioned once it's online!

Best,
Johannes

sialam

  • Robots in Architecture Members
  • Forum User
  • *
  • Posts: 5
    • View Profile
Re: kuka PRC for parametric Laser Cladding
« Reply #4 on: November 12, 2020, 07:48:14 PM »
Hi Johannes
I'm still working on the code you sent me trying to understand each part of it, I'm not sure if I understand everything correctly but also I am configuring the tool, the positioner and everything according to our setup.

I attached our old code which has almost everything already configured according to the post you shared here https://forum.robotsinarchitecture.org/index.php/topic,115.0.html , anyway we cant make that one work. I also attached a draft of how we want the process to run. Which is basically leave the positioner first axis always at 90 degrees, then rotate continuously rotate the second axis and let the kuka robot almost all the time at 90 degrees form the surface of the working piece.

Taking a look at the code you sent me I believe that I might have to change the orientation planes according to the object, process direction and robot tool, right? anyway I will dig more into it .

We are completely new to rhino and Grasshopper, so that is why we are taking sometime in not just making it work but actually understanding the workflow, sorry if that is a but annoying. For sure we Will share with you guys the link of the article.

Kind regards

Syed

« Last Edit: November 12, 2020, 11:44:39 PM by sialam »

sialam

  • Robots in Architecture Members
  • Forum User
  • *
  • Posts: 5
    • View Profile
Re: kuka PRC for parametric Laser Cladding
« Reply #5 on: November 12, 2020, 11:32:48 PM »
Hi Johannes

I've been working in the code and got better results but my toolpath seems to be wrong aligned, I assume that the transformation done ( rotate, orient, rotate) in the code has to be coherent to my turn table and process directions right? how do I evaluate this. I'm trying to understand the whole set of operations.

I put a green rectangle on the part of the code I am talking about, They yellow rectangles represent the code I changed in order to get what seems a better orientation of my whole process. (turntable, piece).

I hope this is a clear explanation.


If not please let me know.

Thanks

Syed
« Last Edit: November 12, 2020, 11:44:48 PM by sialam »

Johannes @ Robots in Architecture

  • Lead Developer
  • Administrator
  • Forum User
  • *****
  • Posts: 1074
    • View Profile
    • Robots in Architecture
Re: kuka PRC for parametric Laser Cladding
« Reply #6 on: November 13, 2020, 01:51:27 PM »
Hello Syed,

That was a bit tricky, the challenge is that when you calculate an angle, you get some value in degrees, let's say 355 degrees and 5 degrees. When the turntable moves from 355 to 5 it will go 350 degrees in negative direction. What you want it to do is to move from 355 to 365, i.e. just 10 degrees.
I made a quick C# script for that, but treat it carefully as I'm pretty sure that there are border-case where it does not work. I only tested that with your current setup.
The rest was pretty straightforward. Just note that there are some positions where the robot runs into A5 limits. Probably some normals of faces are a bit off in the 3D scan, smoothing the scan might help for that.
Also, I would strongly suggest to use ReduceMesh to reduce the complexity of mesh geometry you import into Grasshopper.

Best,
Johannes

sialam

  • Robots in Architecture Members
  • Forum User
  • *
  • Posts: 5
    • View Profile
Re: kuka PRC for parametric Laser Cladding
« Reply #7 on: November 16, 2020, 06:31:34 PM »
Hi Johannes

Sorry for my late reply, Friday we needed to do some stuff and I was not able to work on the programming part of the project. Any how here I am and  I will download the file, scan another part and test it.

I believe we can also reduce the mesh when scanning, I will look at our options in order to have a native file from the 3D scanner, any how I will also test the ReduceMesh in Rhino.

I'll start to work in the scans today and get to you, I appreciate your help.

I'll keep you posted.

Kind Regards
Syed