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.

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.

Ivar Dale, Additive Manufacturing Specialist at FORCE Technology, mentions:

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.

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.

Furthermore, Dale continues:

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. 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 is an economically intelligent, highly effective industrial robotics and robot programming simulator. It 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. To take advantage of the benefits of robotic simulation with RoboDK, visit our website. Check out the blogs and other resources, and explore the range of features available.

Have you ever combined technologies to improve your company’s carbon footprint? Tell us in the comments below or join the discussion on LinkedIn, Twitter, Facebook, Instagram, or in the RoboDK Forum. Also, check out our extensive video collection and subscribe to the RoboDK YouTube Channel.

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Robot arms are capable of anything, limited only by their programming, and will perform mundane and complex tasks, like picking, packing, and inspecting, with greater accuracy and efficiency than any human employee. Additive manufacturing isn’t alone in this; many industries, including aviation and healthcare, are taking advantage of robotic integrations and simulation software for prototyping or to prove their ideas have merit.

You can find programmable robotics in additive manufacturing because they can reduce the environmental impact of production by limiting energy consumption and waste materials. Companies can install robots onto their production floors using RoboDK simulation software and offline programming tools to make them sustainable. These specific innovations make it possible for any business to monitor and adjust their robots from any location, allowing for greater flexibility in additive manufacturing.

By remaining open-minded to the possibilities of robot integrations, manufacturers will discover how they can improve their MRO applications and, by extension, alleviate any sustainability concerns from their industry stakeholders.

Benefits of Industrial Robotics in MRO Applications

Robots are increasingly valuable for MRO applications because they can consistently perform important and complex tasks. Robotic integration can improve a company’s overall productivity because its innovative features tackle inefficient processes throughout production. Integrating robots improve maintenance activities and leads to better safety standards for company employees.

That’s not all, as using robots in additive manufacturing will decrease the environmental impact of production issues as it reduces waste materials and excess energy consumption.

Integrating robots, using RoboDK’s digital twin and simulation, demonstrates the capacity for software automation to increase manufacturing efficiency. The improvements in manufacturing efficiency are possible because automation streamlines processes and removes the need for labor-intensive steps. Essentially, companies are utilizing RoboDK and similar software to employ digital twin technology in their post-processing steps.

In simulations, companies can monitor their product’s performance for a particular use case, grade the performance by simulating use, and catch any oddities as they happen. In other words, companies can design and program virtual prototypes to gauge their product readiness.

Overall industrial robotics help reduce costs in vital areas while improving accuracy and consistency across industry operations.

Challenges Faced When Integrating an Industrial Robot into MRO Applications

Pairing robotics with existing production processes isn’t anything new, but it can still be challenging due to the complexity of each task. Although, they can simplify the job’s complexity using simple programming techniques for each task. To accomplish this task, manufacturers need to hire experienced engineers who understand the fundamentals of robotics and have the capacity to program them accordingly.

As we mentioned, improving MRO applications with robotic integration and simulation software isn’t impossible, but it does require creative thinking from engineers. Improving MRO use cases will require meeting and addressing the challenges of successful integration.

Integration with Existing Systems

Designing a system that works seamlessly with existing equipment can be challenging. Industrial robots became more common in more industries as more innovation occurred. Because of the need for constant business improvement and success, robotic equipment is integrated with:

• Warehouse control systems
• Material handling systems
• And other automated processes

Manufacturing companies can’t afford production delays. With skillful programming, robots comingle and communicate important instructions to existing systems. Having compatible robotic integrations also reduces process errors and helps complete the job without delays.

Flexibility and Adaptability

If industrial robots are to serve the company in MRO applications, they need the capacity to adapt to changing conditions to be successful. Usually, robots can adjust their operations based on different inputs and scenarios, like changes in production levels or customer demand. To adapt, they should respond quickly to new tasks or instructions. Eventually, systems gain benefits like increasing productivity, reduced errors, and maintenance concerns.

Predictive Maintenance

Predictive maintenance is another expected challenge for industrial robot integration. This involves using sensors and other technologies to predict potential problems before they occur. With these predictions, companies can schedule preventive measures before any damage occurs or production levels are affected. So, implementing predictive maintenance strategies will reduce downtime and improve productivity.

Overcoming Integration Challenges with Robotic Simulation Software

Robotic simulation software can help businesses overcome the challenges of integrating industrial robots into MRO applications. By simulating a robot’s environment and tasks, companies can ensure that the robot is programmed to operate correctly and can work for the client. This type of software can also help reduce human errors through improved programming accuracy and faster testing of robot controllers.

In the case of MRO applications, robotic simulation software such as RoboDK can help to improve accuracy and optimize processes. Furthermore, proper robot modeling and simulation can lower the chances of errors when machining, repairing, tooling, and operating on delicate materials, such as those used in laser welding. In laser welding applications where different software must coexist, robotic simulation effectively checks that the operation will function as intended.

Do you have an MRO integration challenge? Tell us in the comments below or join the discussion on LinkedIn, Twitter, Facebook, Instagram, or in the RoboDK Forum. Also, check out our extensive video collection and subscribe to the RoboDK YouTube Channel.

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