And, indeed, should your simulation be highly realistic?

It’s important to understand the delicate balance between realism and usefulness in robotic simulations.

On the one hand, high-level realism allows you to create a more accurate depiction of how the robot will perform in a real-world setting. This helps you to create simulations that more closely match the operating conditions in your facility. On the other hand, striving for absolute realism in your simulation can compromise its usefulness. The simulation can become overly complex and time-consuming, creating a system that is impractical.

The most useful level of realism for your virtual environments is one that accurately reproduces the robot’s task, while remaining streamlined and efficient.

Here’s how to judge and create that level of realism.

What Does It Mean to Have a Realistic Simulation?

Realism refers to how accurately a simulation replicates the real-world behavior and functionality of the robot. This includes the robot’s movement dynamics, interaction with the environment, and operation.

It’s important to understand that a realistic simulation isn’t necessarily one that looks visually pleasing. Qualities of realism like complex lighting and shadows, high-definition rendering, and advanced surface modeling are not usually necessary. While these attributes might enhance the visual appeal of the simulation, they usually don’t contribute to the robot’s performance.

Instead, a realistic simulation should focus on aspects that directly affect the robot’s performance.

Remember, the point of adding realism is not to have an accurate simulation… it’s to have a useful robot.

3 Types of Realism for Effective Robotic Simulation

There are various ways you can look at realism in robotic simulations. For example, you can split it into different types.

Here’s one way to look at 3 types of simulation:

1. Operational Realism

Operational realism refers to the accurate representation of the actual operations of the robots. This involves faithful representation of the robot’s kinetic and dynamic properties and its interaction with the environment.

The primary purpose of operational realism is to create a robot program that will perform optimally in the real-world environment.

2. Visual Realism

Visual realism refers to the accurate graphical rendering of the simulation. With it, you create a visually appealing virtual representation of the real-world environment.

While visual realism might not directly affect the operational effectiveness of the robot, it can be very important for certain applications. For example, if your application uses [robot vision sensors,][RKCAMERA], high levels of visual realism can help you accurately test this sense.

3. Physics Realism

Physics realism refers to accurate modeling of the physical laws that govern the environment where the robot operates. This includes factors like gravity, friction, and collision dynamics that might affect the robot’s performance.

This is one area where you need to strike a balance with your simulation. If you add more physical realism than is necessary, your simulation can quickly become unwieldy.

How Simulation Realism Affects Robot Deployment

When you want to deploy a robot to your workplace, it’s a good idea to start by identifying the level of simulation realism that will be necessary. This will vary depending on your task and application area.

The wrong level of realism in your virtual environment could negatively affect the deployment.

For example, here are some disadvantages to using an overly realistic simulation:

• Increased computational load — Highly realistic simulations use more computational resources, which slows down the simulation.
• Complex debugging — More realism usually leads to programs that are harder to maintain and debug.
• Cost and time — Creating very realistic simulations often takes longer and costs more in terms of computer resources and programming.
• Inaccuracy from overfitting — No simulation is 100% accurate to the real world. As a result, a higher level of realism can actually lead to a worse operation of the physical robot. This is known as “overfitting.”
• Unnecessary details — Any details that are not relevant to the robot’s operation are probably a distraction.

By stripping away unnecessary details from your robot simulation, you can focus on the critical aspects of the robot’s operation and prevent overfitting.

The Realistic Robot Simulation (RRS) Project and RoboDK

In RoboDK, we are dedicated to address a significant challenge in industrial robotics: the need for accurate, easy-to-use robot simulation.

One way we have done this recently is to incorporate the Realistic Robot Simulation (RRS) project. The RRS is an ambitious initiative designed to address the current limitations in the accuracy of offline generated programs for industrial robot.

The primary goal of the RRS is to enhance the precision of robot programs, enabling a more economic and efficient application of industrial robots.

We have created an RRS project add-in which helps to improve the accuracy of robot programs developed with RoboDK. It provides an interface to incorporate accurate robot controller software for motion behavior into offline programming.

Finding the Right Level of Simulation for Your Application

How can you find the right level of virtual environment realism for your robot simulation?

Here are a few tips for finding the right level of realism for your application:

1. Understand the simulation needs for your project — Begin by outlining your project objectives and defining the purpose that your robot will serve.
2. Evaluate your interactions — Consider both the physical and other interactions that your robot will have with the environment and other components in the workspace.
3. Assess the operational environment — Evaluate which elements of the environment need to be included in the simulation.
4. Be realistic about visual realism needs — Look at the rendering and visual requirements of your simulation. Identify what aspects are really necessary.
5. Determine your performance requirements — Identify the level of computing performance required from the simulation tasks. For example, high-precision tasks might need more detailed simulations.
6. Factor in your budget and resources — Lastly, consider your resources and budget. More realistic simulations may demand more computing power and programming skills.

With all of these, strive for balance — a simulation that meets your needs without being “too much.”

Remember, creating realistic robot simulations is fundamental when working with modern robots. By using the right tools, like our RRS add-on, you can create a robot simulation that works for you.

What questions do you have about accuracy and realism in robot simulations? 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

The post Creating Realistic Virtual Environments for Robot Simulation in RoboDK appeared first on RoboDK blog.

In this blog post, we will explore the transformative power of industrial robot arms within the context of Industry 4.0, and how they are propelling the manufacturing industry forward.

Enabling Connectivity and Collaboration in Smart Factories

As Industry 4.0 emphasizes the integration of cyber-physical systems, industrial robot arms serve as the backbone connecting the physical and digital realms. These intelligent machines have advanced sensors and software, enabling them to communicate, collaborate, and coordinate seamlessly with other devices, systems, and human workers.

By enabling connectivity and collaboration, industrial robot arms facilitate the realization of intelligent factories where automation systems work harmoniously, sharing real-time data and optimizing production processes.

Robot Arms: Enhancing Productivity, Flexibility, and Quality

Industrial robot arms bring a multitude of benefits to the manufacturing landscape. With their remarkable precision, speed, and repeatability, these machines can perform various complex tasks with unmatched efficiency.

Their ability to quickly adapt to changing production needs makes them highly flexible and versatile. Moreover, industrial robot arms improve product quality by eliminating human error and ensuring consistent and precise operations. By leveraging these capabilities, businesses can achieve enhanced productivity, greater agility, and high product quality.

Leveraging Real-time Data for Predictive Maintenance and Optimization

In the era of Industry 4.0, data is king. Industrial robot arms play a crucial role in collecting and analysing real-time data from their sensors, allowing for predictive maintenance and optimization of production processes. Moreover, it enables proactive maintenance by continuously monitoring their performance and detecting signs of potential issues, reducing downtime, and minimizing costly breakdowns.

Remote Monitoring and Control for Efficient Operations

Industrial robots can be remotely monitored and controlled, offering businesses a new level of operational efficiency. With centralized management and remote accessibility, companies can oversee and coordinate multiple production sites from a single location. This remote-control capability enables rapid response times to potential issues, reduces the need for on-site presence, and streamlines maintenance and troubleshooting procedures. As a result, organizations can achieve cost savings, increased uptime, and more efficient allocation of resources.

Successful Case Studies

Below are several real-world case studies that exemplify the successful implementation of industrial robot arms and the tangible outcomes accomplished by businesses:

Tesla’s Gigafactory

Tesla, the electric vehicle manufacturer, implemented many industrial robot arms in its Gigafactory for automating various production processes. These robots are used for tasks like welding, painting, and assembly.

By using robots, Tesla significantly increased production efficiency, reduced defects, and improved product quality. Additionally, its implementation also improved worker safety by automating hazardous tasks.

Amazon’s Fulfillment Centers

Amazon: the e-commerce giant, employs thousands of industrial robot arms in its fulfillment centers. These robots are responsible for picking, packing, and sorting items for shipment. By using robot arms, Amazon has been able to greatly speed up order fulfillment, leading to faster delivery times for customers. They work alongside human workers, allowing for a more efficient and streamlined operation.

BMW’s Production Line

BMW, the automotive manufacturer, incorporated industrial robot arms into its production line for tasks such as welding painting, and assembly. The robots work collaboratively with human workers, enhancing productivity and precision. BMW has reported improved production quality, reduced cycle times, and optimized resource utilization through the implementation of robot arms.

The Future of Industrial Robot Arms in Industry 4.0

The future of industrial robots within the Industry 4.0 landscape is promising. As technologies such as artificial intelligence, machine learning, and advanced sensors evolve, robot arms will become even more intelligent and autonomous. This will lead to adaptive decision-making, enhanced human-robot interaction, and improved safety measures. Integrating them with other emerging technologies, such as augmented and virtual reality, will expand their capabilities, allowing for more immersive programming, simulation, and training experiences.

Conclusion

Industrial robot arms are undeniably driving the future of automation in the Industry 4.0 era. Their connectivity, collaboration, and adaptability empower businesses to create intelligent, efficient, and connected manufacturing environments. By embracing these technologies, companies can gain a competitive edge, achieve higher productivity and reduce costs. And stay ahead in the rapidly evolving landscape of industrial automation.

To fully unlock the potential of industrial robots in your manufacturing processes, visit robodk.com. RoboDK offers cutting-edge software solutions that streamline robot programming, simulation, and optimization. With RoboDK’s intuitive platform, you can unleash the full capabilities of industrial robots.

Remember, the future of manufacturing is here, and industrial robots power it. Take advantage of the opportunity to revolutionize your operations and stay at the forefront of innovation.

Follow us on LinkedIn, Twitter, Facebook, Instagram, or in the RoboDK Forum.. Also, check out our extensive video collection and subscribe to the RoboDK YouTube Channel

The post The Transformative Power of Industrial Robot Arms in Industry 4.0 appeared first on RoboDK blog.

The world of offline programming has just entered the age of virtual reality, thanks to our recent software update. With the new VR functionality, you can now immerse yourself in the virtual world of your robot workstation.

Although VR is new to offline programming, it already exists in some industrial applications. Some of these applications are already changing industries and others are set to become big in the near future.

Here are 10 industrial tasks that will be transformed by the newest wave of virtual reality technology.

1. Enhanced Virtual Meetings

You could say that communication has been the main driver for many of the modern technologies that we now take for granted. Video conferencing, social media, customer service messaging, they all help us to communicate more effectively with our fellow humans over the internet.

It makes sense that virtual reality meetings are the next step. Many companies are actively trying to find ways to reduce their carbon emissions and reducing international travel is certainly one way to do this. VR meetings allow for an enhanced meeting environment compared to other video conferencing options.

2. Low-Cost Workplace Training

Training is one of the most exciting industrial applications for VR, especially for dangerous or costly-to-train jobs. The virtual environment allows you to train your workers in a very realistic environment much more cheaply than, for example, creating a physical mock-up of the work location.

Of course, one type of virtual reality has been used in the aerospace industry for years. Pilot-training has long been done with flight simulators, which are essentially advanced VR systems. However, any business can use VR for training. Walmart has recently deployed VR units to 5000 of its stores to train its managers.

3. Next-Level Customer Engagement

Are you a robot integrator? Do you design products which benefit from a “test drive” before purchase? What could you achieve if your customers could try out your product before you had even built it?

Virtual reality has a real potential to improve customer engagement by letting them interact with a virtual model of your product. For custom products, this could turn out to be a game-changer. For example, as a robot integrator, it’s much more cost-effective to change the RoboDK model of your solution than it is to build and program the physical robot… only for the client to then request changes.

IKEA has already started using VR to allow customers to “try out” their kitchen design.

4. Immersive Engineering Design

The virtual environment doesn’t only help the customers to engage better with your design. It can also help you as the designer to better understand your own design.

Virtual reality engineering has actually been around for some time. Jaguar Land Rover, for example, was using it as far back as 2006. VR allows us as engineers to get detailed feedback about the strengths and weaknesses of our designs before the costly phase of building physical mock-ups. Of course, VR will never replace physical mock-ups completely but it can improve the efficiency of the entire engineering process.

5. Remote Equipment Diagnostics

One interesting industrial application involves improving remote diagnostics and maintenance tasks with VR. One way is to use it in collaboration with Augmented Reality — where virtual objects are overlayed in real-time over a video image of the real environment. In this way, an expert maintenance engineer can remotely guide a non-expert worker to perform diagnostic and maintenance tasks.

6. Robot Selection

We have already mentioned how VR can help your customers to “test drive” your products in a virtual environment. The same benefit applies to you as a customer. For example, when you are trying to decide which model of robot you want to purchase, VR can provide a great way to do that.

We often talk about the fact that RoboDK can be used to try out different robot models with your application before you purchase the robot. Imagine how much better you could test the robot by experiencing it in an immersive virtual environment!

7. Immersive Events and Conferences

A rising trend in conferences is to provide an alternative, online experience for those people who cannot attend in person. Until now, these virtual alternatives have been a less-than-wonderful experience. But, virtual reality conferences look to change all that.

As one journalist attending a VR conference explained, the experience is still not perfect but it is certainly more immersive and looks set to be part of the future of conferences, trade fairs, and other industry events.

8. Debuggable Assembly Steps

Many products require some assembly steps in their manufacture. Traditionally, the only good way to “debug” this process was to make a physical prototype of the product and try out the assembly steps yourself. Of course, this will always remain part of the design process for physical products.

Virtual reality adds an additional, valuable test stage by allowing engineers to test the assembly steps in a virtual environment. This is more realistic than just testing the assembly in your CAD package and lets you deal with potential assembly problems before they arise.

9. Construction Design

The advantages that we mentioned above with respect to engineering design are also applicable to the construction industry. We have talked about construction robots a few times here on the blog (mostly with regard to robotic 3D printed architecture).

VR is already starting to change the construction industry by allowing architects to “walk through” the construction site and experience their design before a single drop of concrete has been poured.

10. Programming Robots

Many of the examples listed above can already be found in use in some industries. But, the industrial application that we are most excited about here at RoboDK is using VR to program your robot.

You can try it out for yourself by downloading the latest version of the software, which includes VR support for the very first time.

What industrial application do you think could benefit from VR? Tell us in the comments below or join the discussion on LinkedIn, Twitter, Facebook, Instagram or in the RoboDK Forum.

The post 10 Industrial Tasks that Virtual Reality Will Transform appeared first on RoboDK blog.

Virtual reality (VR) has been gradually making its way into businesses over the last decade. As VR technology has gotten smaller, better, and cheaper, the number of industrial applications has grown. Industries as diverse as health care, retail, defense, logistics, construction, and automotive are already on-board.

However, although the technology is cheaper and better than it has ever been in the past, there is still an initial cost. If you want to try out virtual reality for yourself, you’re going to have to invest in some new technology.

If you want to try out our new VR feature in the latest version of RoboDK, you’ll have to buy, borrow, or rent some VR kit.

Here’s an introductory guide to the tech you will need for virtual reality robot programming.

The High, Medium and Low End of VR Technology

Almost every virtual reality system is based around a headset. This is strapped around your head and contains a screen which is held a few centimeters from your eyes.

But, before you can get a VR headset strapped around your head, the first hurdle is getting your head around the different types of VR headset!

There are at least 4 different options:

Ultra-High-Tech: Full Body Immersion

The ultra-high-tech option involves kitting out an entire room with detailed body trackers and equipping the user with haptic vests. Using custom-designed tools that are tracked in the real-world, the users can interact very realistically in the virtual environment, both with the virtual world and with other users who are in the room with them.

This ultra-high-end of VR is brand new — the only company I know is doing it is startup Sandbox VR which was Series A funded in early 2019. It is also almost certainly far too advanced for such a simple task as offline programming a robot.

The next step above this is probably “full dive VR” which would use a brain-computer interface and is still a long way off.

High-Tech: Immersion and Presence

The most accessible high-tech option is a dedicated VR headset and tracking system. There are several of them on the market. The most well-known are probably the Oculus Rift S and HTC Vive, both of which we’ve tested in RoboDK.

These offer the most comfortable, immersive virtual environments available in the consumer market. Unlike cheaper options, they give you a feeling of virtual “presence” as they track your position in the room, not just “immersion” which is provided by the headset.

They tend to cost around $500+ to purchase.

Medium-Tech: Immersion

There are a ton of medium-range VR headsets available on the market from a huge number of manufacturers. Think of the name of any tech company and they’ve probably got a VR headset. Examples include Samsung Gear, Lenovo Explorer, Acer WMR, HP Reverb, and Dell Visor.

The differences between these headsets vary wildly. Some, such as Samsung Gear, are a single step up from the Google Cardboard (see below) and use your smartphone as the screen. Others have capabilities that near the high tech category.

They tend to cost between $75 to $500 to purchase.

Low-Tech: A Quick, Cheap Way

The cheapest option is to use Google Cardboard or headsets working on a similar principle. These use your smartphone as a screen and provide lenses which focus the images from the phone onto your eyes but no extra sensors. Often, they have a button which presses the screen for you, but that’s all the interaction you get.

These are very low-tech — Google Cardboard is literally made of cardboard — and the feeling of immersion is not as good as with more expensive options. However, they are a low-cost way to try out VR for yourself.

They tend to cost between $2 to $30 to purchase.

What’s Compatible With RoboDK

The new virtual reality feature in RoboDK should be compatible with any headset that works with SteamVR/OpenVR. This is because we used the OpenVR library to develop it, which is compatible with a range of different headsets (though it’s difficult to find a definitive list).

At the time of writing, we have tested the new feature with the Oculus Rift S and the HTC Vive, but it should also work with other headsets.

For cheaper options, including Google Cardboard, you would need to use a program like RiftCat which allows your PC to stream its display to your smartphone.

5 Options for Trying Out the VR Feature

If you’ve already got a VR headset then you can try out RoboDK’s new feature immediately.

But, what if you don’t have one? There are a few options to try out VR tech.

1. Buy a Medium to High-Tech Headset

Of course, you could just jump straight in and buy a high-tech VR headset. This will be a good option if you have already decided that you want to add virtual reality capabilities to your business and have just been looking for a good excuse to get started. Now is your chance!

2. Rent a High-Tech Headset

There are a lot of rental options for virtual reality. Rentals are a good way to “try before you buy” are usually around $10 to $40 a day. Remember to check that your computer specifications match the requirements of the VR system, as most of them use your computer’s graphics card. If not, some rental companies also rent out VR-ready laptops.

3. Borrow One

You might know someone who has a VR system already and could lend you it for a day or two. Reach out to your network and ask if you can try it out.

4. Buy a Low-Tech VR Headset

You don’t necessarily have to invest in the high-tech options. You could spend $20 to $100 on a lower-tech headset, such as Samsung Gear, which will allow you to get a feel for VR. Just remember that the experience is quite different. If you plan to use RoboDK for VR for several hours on end — though always remember to take breaks — this is not going to be very comfortable with lower-tech options.

5. Make One

Finally, you could make your own VR headset! There are various designs and kits for Google Cardboard and similar sets which can be bought for only a few dollars online. As with the other low-tech options, the experience is not perfect but it is a cheap way to get a feel for what might be possible.

There really should be nothing holding you back from trying out robot programming in a VR environment. Once you’ve got a headset, download the latest version of RoboDK to try out the new feature!

Have you tried VR? What was it like? Tell us in the comments below or join the discussion on LinkedIn, Twitter, Facebook, Instagram or in the RoboDK Forum.

The post What Tech You Need to Use RoboDK’s VR Feature appeared first on RoboDK blog.

In the latest release of RoboDK, we’ve introduced support for Virtual Reality (VR) headsets. For the very first time, this allows you to get “up close and personal” with your robot simulation when doing offline programming.

The question you might be asking yourself is… Is VR “worth it” for me?

Maybe you are in two minds about VR technology:

1. You might think that VR is just a “fun toy.” A fleeting fad which will never become as popular as all the hype says it will. Surely, VR will just go the way of Google Glass a technology that supposedly “died” in 2015?…
2. You might be enthusiastic and keen to use VR with offline programming. Maybe you’re already using VR. Maybe you’ve just heard about it and you want to get started as soon as possible.

Alternatively, you might just be unsure. Is VR really going to benefit your business? Let’s have a look.

What is Virtual Reality?

Virtual Reality technology has been around for a surprisingly long time. It’s almost as old as robotics! The first VR headset that resembled the headsets we use today was actually invented in 1968.

Even so, VR is still quite a new concept for most people. You might have seen a demo at a trade fair or science museum but you probably don’t see VR in your day-to-day life… yet.

The technology has advanced a lot over the last decade. I remember trying out the first ever Oculus Rift developer kit back in 2012, which my research colleague had ordered for a project. The experience was a bit clunky but it was the first time that I could imagine the future of home VR. The systems I’d tried before required a whole roomful of tracking technology. This just needed a headset.

Oculus is one of the headsets that we now support in RoboDK. The technology is now much more advanced than it was when I tried it 7 years ago.

Industrial VR

Most of the advertising for VR is currently targeted at the games market. However, you’d be wrong to think that the technology is only good for playing games.

Industrial VR has been making waves in various industries for a few years now and the benefits are perhaps even more important than in consumer applications. It involves using the same VR headsets but applying them to industrial tasks.

Common examples of industrial applications include:

• Training — This is a big one. Workers are trained in a virtual environment where it doesn’t matter if they make mistakes.
• Product Testing — Digital prototypes can be used to test product designs without having to build any product at all. For example, Ford uses VR to test out the customer experience in digital models of their cars.
• Product Design — VR adds an extra dimension to product design which can improve the design from the beginning. CNH Industrial, for example, has used VR to model agricultural machinery since 2017.

Sure, the industrial applications of VR might not seem as fun or flashy as the consumer applications. But, the technology is fast becoming an indispensable tool for many businesses.

Oh yes… and don’t believe everything you read about the supposed popularity of these new technologies. You know that Google Glass technology which apparently “died” in 2015? It’s also still alive and thriving in industrial applications as Google Glass Enterprise. It’s been quietly improving productivity in businesses for 4 years now. Sometimes, the industrial uses are far more successful than the consumer ones.

Is VR Really Useful for Offline Programming Robots?

“Okay,” you might be thinking, “VR technology is quite well established in some industries… but is it really useful for offline programming robots?”

The honest answer is “you’ll have to try it to find out.”

As with many of these new technologies, it’s only when we test them out in our real processes that we are able to appreciate their effects on our business. To continue with the example of Google Glass Enterprise (which, to avoid confusion, is actually Augmented Reality, not Virtual Reality). Manufacturer ACGO started using the technology to reduce production time but simultaneously halved training time which was a complete surprise to them.

This type of unexpected gain is common with the “newer” (or let’s say “less established”) technologies. Our VR support in RoboDK is a brand new feature, so we can’t tell you exactly how much it will change your process… yet.

However, there are some preliminary benefits from other industrial VR applications which suggest that there could be significant benefits. For example, Walmart found that VR training improved employee learning by 10-15%. Manufacturer recently Genlab achieved a 20% annual production increase using a VR factory.

How RoboDK Supports Offline Programming

We’ve added support for VR using the OpenVR toolkit. This is a library which sits between RoboDK and your VR hardware, allowing you interact with the simulation environment.

What this means for you is that our VR support is riding on the back of an already well-established VR interface. We haven’t tried to develop our own VR library, which would be a recipe for a buggy, difficult experience. Instead, we’ve gone for a library which has over 4 years and hundreds of hours of VR coding, expertise and testing behind it from Valve, one of the most established computer game developers of the last 20 years.

This also means that a range VR headsets are supported “out the box”, including Oculus Rift, HTC Vive, Samsung Gear VR, and more. Any device supported by OpenVR/SteamVR should work.

We’ve already tested RoboDK with the Oculus Rift S and HTC Vive headsets with RoboDK, and they’re working well!

How You Can Try Out the New VR Support

The best way is to try it out VR is to try it out for yourself by selecting Connect-Connect VR Headset (make sure to have SteamVR installed). Obviously, there is a technology investment in the VR headset, although there are cheaper options for trying out the technology which we’ll cover in a later article.

If you have got a VR headset already, just download the latest copy of RoboDK and try out the new feature for yourself!

What are your thoughts on VR in industry? Tell us in the comments below or join the discussion on LinkedIn, Twitter, Facebook, Instagram or in the RoboDK Forum.

The post Yes, Virtual Reality Now Works With Offline Programming appeared first on RoboDK blog.