Design of Iron Cast Deburring Robotic Cells with Simulation and Offline Programming Tools

The design of last generation anthropomorphous robots manufacturing cells is a challenging activity, to be developed accurately in a fast and effective way due to the strong requirements to satisfy in terms of time to market, overall performances and the total costs of the final application. During the design stages, different types of graphical and technical representations are needed to exalt and communicate the design intent and to evaluate the effects of every design variant on the final operating performances. For this reasons the choice of the tools to adopt, and a correct methodology for an integrated use, for this purpose is strategically important and delicate. On one side the design tools must be focused to point out all the multidisciplinary effects involved, especially those concerning the strong interrelation of the mechanical apparatus solutions with the electrical and electronics systems, while on the other side they must be absolutely integrated and easy to use. In the present paper it will be explained the choices effected on the graphical representation and design tools, and the design method created for an effective integrated use, in the design and development of iron casts deburring anthropomorphous robots manufacturing cells, performed during real experiences, developed together by DIMEC University researchers and SIR, an important system integrator enterprise. Actually, state of the art 3D parametric CAD and behavioural simulation design tools confirmed to be powerful but the adoption of anthropomorphous robot simulation and offline programming tools proved to be fundamental for the final validation of every design variant. The need to enrich classical mechanical design representation, static and fixed for single configurations, with animations where robot movements and the motion control can be effectively communicated and evaluated, was then solved and proved to give an important feedback to the design engineers, who acquired more consciousness on the real performances achievable. Furthermore, the availability of multimedia movies, was finally appreciated even to interact with the final user for training purposes.