System and method for programming robots

A robot programming system comprising:

• at a first location comprising a teaching station, a teach arm and a table having a fixture plate, wherein teach data is prepared to teach motions to a robot to drive an end effector through a series of desired path points along a desired path of motion with respect to an application station, said teach data comprising at least one of robot position data elements and at least one of robot motion pattern data elements;
• at a second location comprising said application station, said second location being different from said first location, a robot and a device having a fixture plate, wherein said teach data is communicated to said robot and said robot is programmed in accordance with said teach data to drive said end effector through said series of desired path points along said desired path of motion with respect to said application station;
• at said teaching station, a programmed robot simulation to drive an end effector model through a series of model path points along a model path of motion with respect to said teaching station, the model path points and model path of motion corresponding to desired path points and a desired path of motion;
• and
• at said first location:
• an end effector model that moves through a series of model path points along a model path of motion with respect to the teaching station, the model path points and model path of motion corresponding to desired path points and a desired path of motion;
• an encoder for furnishing model path point data representative of the position and orientation of the end effector model with respect to the teaching station at each of the model path points as the end effector model is moved through the model path of motion, the encoder defining an encoder kinematics;
• an electronic memory for storing data, including:
• simulation software memory for storing robot simulation and motion program generation software for a robot simulation defining a robot kinematics;
• model path point memory for storing the model path point data;
• and
• motion program memory for storing robot motion-control program segments;
• and
• a programmable computer coupled to the encoder and to the electronic memory, including:
• a motion program processor for executing the robot simulation and motion program generation software as a function of the model path point data to generate robot motion-control program segments for causing the robot to drive the end effector through the desired path of motion, and for storing the robot motion-control program segments in the motion program memory.

A robot programming system for thermal spray coating a workpiece, said system comprising:

• at a first location comprising a teaching station, a teach arm and a table having a fixture plate, wherein teach data is prepared to teach motions to a robot for thermal spray coating said workpiece, said teach data comprising at least one of robot position data elements and at least one of robot motion pattern data elements;
• at a second location comprising an application station, said second location being different from said first location, a robot and a device having a fixture plate, wherein said teach data is communicated to said robot and said robot is programmed in accordance with said teach data for thermal spray coating said workpiece;
• at said teaching station, a programmed robot simulation to drive an end effector model through a series of model path points along a model path of motion with respect to said teaching station, the model path points and model path of motion corresponding to desired path points and a desired path of motion;
• and
• at said first location:
• an end effector model that moves through a series of model path points along a model path of motion with respect to the teaching station, the model path points and model path of motion corresponding to desired path points and a desired path of motion;
• an encoder for furnishing model path point data representative of the position and orientation of the end effector model with respect to the teaching station at each of the model path points as the end effector model is moved through the model path of motion, the encoder defining an encoder kinematics;
• an electronic memory for storing data, including:
• simulation software memory for storing robot simulation and motion program generation software for a robot simulation defining a robot kinematics;
• model path point memory for storing the model path point data;
• and
• motion program memory for storing robot motion-control program segments;
• and
• a programmable computer coupled to the encoder and to the electronic memory, including:
• a motion program processor for executing the robot simulation and motion program generation software as a function of the model path point data to generate robot motion-control program segments for causing the robot to drive the end effector through the desired path of motion, and for storing the robot motion-control program segments in the motion program memory.