Digital engineering methods for enhanced flexibility of robofacturing (robotic manufacturing) applications

A digital engineering method was developed to enhance robotic cell flexibility in industrial manufacturing applications. Computer Aided 3D parametric modeling, behavioural simulation, offline programming were integrated into the design process to define and generate robotic cell virtual prototypes. Resulting information and data were primarily used during design and engineering stages for optimizing the cell layout and for assuring best performances in cycle time reduction and manufacturing path accuracy. Then digital models were simplified and fit within customizable virtual environment, developed for allowing final users to quick re-configure the robotic cell and re-program robots without any specific competence on robotics. The robotic deburring and finishing manufacturing of crankshaft for V8 and V12 high-performance engines was investigated through the method developed. A cell prototype was finally realized by R&D engineers from SIR S.p.A. (www.sir-mo.it) and researchers from the Department of Mechanical and Civil Engineering, sharing competences, experiences and technical resources within the Integrated Design and Simulation of Robotic Systems Lab, a novel Industry/University hybrid structure. Such digital engineering method applied to a robotic manufacturing problem leaded to the theorization of a “Design for Robotic Manufacturing (“Robofacturing”)” approach, finally called. Robotic cell flexibility was enhanced providing final users a digital engineering service for manufacturing cell re-configuration and robot re-programming.