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 Generate target 3D models for each process phase in the 3D modelling environment (Autodesk Inventor):  1) fresh mould  2) cut out 1/4 from fresh mould  3) cut out 2/4 partly machined mould  4) cut out 2/4 partly machined mould  Preview models in each phase to capture reference surface data for interactive measurements  Generate toolpaths in Cam environment (MasterCam)  Use 3D models for all machining phases  Finalize the paths with a robot simulation/post-processing tool (RoboMaster, ConiferRob, …)  approach and departure points to robot program  details for variables such as workpiece positioning and tool data  simulation with reachability and singularity check  post-processing and downloading to the robot controller  Interactive and iterative program execution  Set markers (manually)  Detect markers with robot vision and locate the target in robot space  Machine the target segment

Figure 1. Usage scenario of the interactive localization method.

The planning and programming of the sensor operations relied on general CAD tools, which are easy to implement and use and applicable to sensor programming for automatic task execution. Interactive task execution takes additional time and extends the task execution time of the robot system in the range of several seconds to several tens of seconds. In many cases, especially in highly flexible and close to one-of-a-kind production, this can be acceptable. Due to the complexity of the environment and frequent changes, however, this may be the only feasible way to introduce robotic technologies to heavy-duty industrial applications, in many cases removing otherwise inevitable ergonomically problematic and hazardous working conditions.

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Exploitation potential The interactive sensor system can be exploited in many kinds of localization applications with the following prerequisites: • The located workpiece should contain large enough regular reference features. • A tool should be available to pick reference points from the features, e.g. in a CAD image. • The localization time could reach several seconds or, for complicated shapes, tens of seconds. • The accuracy requirement should be at the level of 1–2 mm at a measurement distance of 5 metres.

VTT Research Highlights 3  

Production matters. VTT in global trends. Kai Häkkinen (ed.)

VTT Research Highlights 3  

Production matters. VTT in global trends. Kai Häkkinen (ed.)