Selection and Optimization of the Parameters of the Robotized Packaging Process of One Type of Product

Abstract

The article presents the results of computer simulations related to the selection and optimization of the parameters of robotic packing process of one type of product. Taking the required performance of the robotic production line as a basis, we proposed its configuration using the RobotStudio environment for offline robot programming and virtual controller technology. Next, a methodology for the validation of the adopted assumptions was developed, based on a wide range of input data and a precise representation of the applicable conditions in the packaging process of one type of product. This methodology included test scenarios repeated an appropriate number of times in order to obtain the result data with the desired reliability and repeatability. The main element of the research was a computer simulation of the station based on the Picking PowerPac package. It was assumed that the products on the technological line are generated pseudo-randomly, thus reflecting the real working conditions. The result of the conducted works is the optimal operating speed of industrial robots and conveyors. The developed methodology allows for multifaceted analyses of the key parameters of the technological process (e.g., the number of active robots and their load, speed of conveyors, and station efficiency). We paid special attention to the occurrence of anomalies, i.e., emergency situations in the form of “halting” the operation of chosen robots and their impact on the obtained quality of the industrial process. As a result of the simulations, numerical values were obtained, maximum efficiency, with regard to maximum overflow of items of 5%, for LB algorithm was equal to 1188 completed containers per hour, with conveyors speeds of 270 mm/s and 165 mm/s. This efficiency was possible at robot speeds R1 = 6450 mm/s, R2 = 7500 mm/s, R3 = 6500 mm/s, R4 = 6375 mm/s, R5 = 5500 mm/s, R6 = 7200 mm/s. The ATC algorithm reached efficiency of 1332 containers per hour with less than 5% overflown items, with conveyor speeds of 310 mm/s and 185 mm/s. This efficiency was possible at robot speeds R1 = 7500 mm/s, R2 = 7500 mm/s, R3 = 7200 mm/s, R4 = 7000 mm/s, R5 = 6450 mm/s, R6 = 6300 mm/s. Tests carried out for emergency situations showed that the LB algorithm does not allow for automatic continuation of the process, while the ATC algorithm assured production efficiency of 94% to 98% of the maximum station efficiency.

Modelling and simulation of robotic production systems

“…The complexity and diversity of elements included in robotic work cells and production lines mean that applied methods and tools should support both the design of new systems and the reorganization of existing ones [1]. The development of robotics has forced progress in the field of programming industrial robots [2][3][4]7,9,11,19,22]. Programming industrial robots can be done in two ways, i.e.…”

“…The other disadvantages are discrepancies between the virtual model and reality, other robot motion trajectories (this is especially visible when setting the default non-dedicated robot controller), online testing of programs and their possible modification, additional offline and online programming skills. The robot programming process is iterative especially when one wants to somehow optimize the prepared program [3,5,13,15,17,20,[23][24][25].…”

Controlling an Industrial Robot Using a Graphic Tablet in Offline and Online Mode

“…The high level of automation and robotisation of modern production lines leads to a search for innovative methods of programming and machine control. This is particularly important in the context of industrial robots, whose operating systems and programming languages provide great freedom in the development of advanced control software [ 1 , 2 , 3 , 4 ]. The rapid acceleration of technological progress makes it difficult for process line operators to keep up with the exponentially increasing capabilities of the machines they operate.…”

Industrial Robot Control by Means of Gestures and Voice Commands in Off-Line and On-Line Mode

“…During the implementation of industrial processes, it is necessary to take into account many technological and hardware parameters [4][5][6][7]. A great challenge is to achieve high productivity and product quality in relation to the costs incurred for the construction of production lines and production itself.…”