System and method for the automatic generation of robot programs

A method for the automatic, computer-assisted generation of workflow charts for processing a work piece with a tool using an industrial robot, the method comprising:

• preparing an initial chart with a plurality of tool paths for a work piece in a specific target position and for specific process parameters that impact the processing of the work piece, a tool path defining a target movement of the tool along the work piece;
• defining a state space describing variable parameter values that impact the processing of the work piece, wherein each point in the space represents a specific combination of potential parameter values;
• discretizing the space into individual states;
• simulating the processing of the work piece using the initial chart for one or more discrete states and analyzing a result of the simulated processing based on a pre-definable criterion;
• iteratively modifying the initial chart and subsequently simulating the processing of the work piece using the modified chart for at least one discrete state, and evaluating the result of the simulated processing based on a pre-definable cost function;
• and
• performing the iteratively modifying step until the cost function reaches a minimum or drops below a threshold value, indicating that an optimized chart for the respective state has been identified.

A method for the automatic, computer-assisted generation of workflow charts for processing a work piece with a tool of an industrial robot, the method comprising:

• providing an initial chart containing a plurality of tool paths for a work piece in a specific target position and for specific process parameters that describe the processing, wherein a tool path defines a target movement of the tool along the work piece;
• defining a state space, which describes possible sequences and starting times for the tool paths of the initial chart, wherein each point in the state space describes a specific sequence having a specific starting time;
• discretizing the space into individual states;
• simulating the processing of the work piece using the initial chart for different, discrete states, and analyzing a result of the simulated processing according to a pre-definable criterion;
• iteratively modifying the initial chart, then simulating, factoring in a movement that superposes the work piece, the processing of the work piece using the modified chart for at least one discrete state and evaluating the result of the simulated processing according to a pre-definable cost function;
• and
• performing the iteration until the cost function reaches a minimum or drops below a threshold value, indicating that an optimized chart for the respective state has been identified.

A method of controlling a robot for processing a moving work piece by way of a tool using an industrial robot according to a chart containing a plurality of robot motions defined by path points, wherein each path point is assigned a target position of the work piece, the method comprising the following steps, to be performed during an execution of a robot motion:

• measuring an actual position of the work piece and determining a speed of the work piece;
• calculating a current target position of the work piece for the current position of the robot using the target positions of the work piece that are assigned to the path points;
• calculating a difference between the target position and the actual position of the work piece;
• determining a next target position of the robot to be reached, and a time at which the next target position is to be reached, so as to decrease or minimize a difference between the target position and the actual position of the work piece.