Virtual commissioning is becoming a key tool for adding robots to your manufacturing process. But fragmented hardware can hold you back… which is what the PeneloPe project at UNIMORE addresses.
The rise of virtual commissioning is no surprise to us at RoboDK — we have been promoting the use of simulation technology for robot deployment for the past decade!
A persistent challenge in robot deployment is the lack of cohesive integration between hardware components. One example is the fragmentation between Programmable Logic Controllers (PLCs) and robot controllers.
Addressing this critical challenge, researchers from UNIMORE are using RoboDK to bridge the gap as part of the Europe-wide PeneloPe project.
Introducing… UNIMORE and PeneloPe
This RoboDK project involves researchers from the University of Modena and Reggio Emilia (UNIMORE) in its Department of Sciences and Methods for Engineering (DISMI).
UNIMORE
The University of Modena and Reggio Emilia in Modena, Italy is at the forefront of blending engineering principles with practical applications. Part of the research mission within DISMI is to transfer research knowledge into civil society and the business landscape.
PeneloPe
The PeneloPe project is an ambitious initiative funded by the European Horizon 2020 program. It is supported by a collaborative network of partner companies specializing in sustainability, automation, and other manufacturing technologies.
The project aims to revolutionize the manufacturing sector through the development of a closed-loop digital pipeline. Central to the UNIMORE team’s contribution in this project is the integration of industrial robots into this digital pipeline.
The Challenge: Coordinating PLCs and robot controllers
A common challenge when deploying robotic systems is the fragmentation between hardware components. This lack of standardization often complicates the process of integrating robotic technologies — in fact, solving this problem is one of our core drivers at RoboDK.
The researchers at UNIMORE identified a particular combination of hardware that is often a challenge: PLCs and robot controllers.
In this research, the team noted that effective coordination between these two components is critical. Manufacturers are often under pressure to reduce their time to market. However, integration can be difficult and time-consuming when components are made by different brands.
The team focused on creating a unified method and software workflow for simulating multi-brand robotic systems.
The System: RoboDK, KUKA, and TwinCAT
The solution created by the researchers combines a few core hardware and software components into a single integrated system:
The Hardware Components
Core hardware components include:
- KUKA KR210 R2700 Prime Robot — This versatile industrial robot from KUKA provides the core robotic hardware for the solution.
- Tool Warehouse — The tool warehouse provides an organized space and swift access to multiple tools for the various stages of the production process.
- Spindle Tool — For machining operations, such as deburring, the spindle was used for the team’s test case application.
The Software Components
Core software components of the system include:
- RoboDK Robot Simulator — At the center of this solution is RoboDK. As well as its powerful offline programming and simulation capabilities, RoboDK provided key functionality for allowing multi-brand component compatibility.
- Beckhoff TwinCAT — Use for PLC development, TwinCAT provides a platform to create industrial programs and handle data exchange.
- ROS2 Connector — The team also developed an enhanced version of the system that uses the Robot Operating System (ROS) as a system coordinator.
- Python Communication Bridge — The team developed a communication bridge using the Python programming language to manage real-time I/O signal synchronization between RoboDK and the PLC using TwinCAT.
5 Potential Benefits and Impacts of the Team’s Solution
The solution proposed by the team at UNIMORE offers several potential benefits for manufacturers looking to deploy multi-brand automation solutions, including:
- Enhanced Efficiency — Creating a single combined system for PLC and robot communication means that the team has made robot deployment more streamlined and efficient.
- Cost Reduction — Virtual commissioning through RoboDK and the system reduces the cost of robot integration by allowing engineers to optimize their in simulation, reducing downtime.
- Accelerated Time-to-Market — By streamlining coordination between PLC and robot controllers, the system can speed up the time to bring new solutions to market.
- Improved Flexibility — Focusing on multi-brand automation solutions is a powerful move as it addresses the core challenge of interoperability that can often be a challenge for automation engineers.
- Broader Applications — The test application for this implementation was deburring of a cast iron component. However, it can apply to many more applications. The team is already working on using it for an Aerospace Pilot Line as part of the PeneloPe project.
Next Steps for the Project
This project by the team at UNIMORE has provided a core foundation for future developments as part of the PeneloPe project. With its ROS2 integration, the team hopes to open up new pathways for task coordination and system management to elevate the tool’s capabilities.
Within the PeneloPe project, the next step is to apply the system to manufacturing of an Aerospace Pilot Line that addresses assembly of the lower part of an airplane fuselage.
Using RoboDK in Your Research Project
Do you have a research project that could benefit from RoboDK’s extensive functionality?
This project from the team at UNIMORE is just one of many robotics research projects that use RoboDK. Your project could be the next!
RoboDK has been a valuable tool in the PeneloPe project, enabling us to efficiently simulate custom robotic cells and their complete control software from the preliminary phases. Its easy integration with external software has allowed for faster development and commissioning, explains Pietro Bilancia, Professor of Mechanical Engineering at UNIMORE.
The software’s simple interface and powerful API interface allow you to extend the software’s core capabilities with your own developments, and avoid reinventing the wheel.
If you’d like to download all the tools for the virtual commissioning of flexible robotic cells, you can find all the instruction and materials here.
To try out RoboDK, just download a free trial copy and try it out for yourself. We also have an educational license for academic researchers.
What industrial components do you often have challenges integrating? 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