Metrology Assisted Robotic Automation 2

This paper details the motivation, design and outcome of the Metrology Assisted Robotic Automation 2 (MARA2) project. This project builds on the MARA project, a previous research project at The Manufacturing Technology Centre (MTC), in which a real-time correction system for industrial robots was proven successfully without End-Effector loading. MARA2 aims to assess the viability of using an external measurement system to correct an industrial robot’s position under load during machining and trimming operations. Using the MARA dynamic correction system, a robot can be made accurate over a large volume. Robot accuracy is important when using Offline Programming (OLP) to generate paths for robots. This system could be used as a more cost efficient replacement for large purpose machine tools or to replace manual work that was previously out of reach of robot accuracy specifications. The MARA2 project conducted a review into the current large volume metrology market and down selected the most suitable device for the system. An existing cell was then converted into a robotic machining cell with integrated spindle. A new, simplified programming workflow was created, using a traditional Computer Aided Manufacturing (CAM) system, robot simulation and bespoke calibration software. The system was then used to machine various feature geometries into aluminium, which were then measured and compared to non-compensated cuts. Trial results show feature accuracies of within 0.2mm are achievable in aluminium milling operations.