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In the engineering practice of performing robotic measurements with a 2D scanner, a major difficulty is to accurately determine the tool center point (TCP) quickly and easily since it does not exist as a physical object. The article proposes an algorithm for determining the coordinates of the TCP point. It relies on the possibility of using a conical element, such as a milling cutter of unknown geometry. So far, the algorithms found in the literature were based on a sphere of known size. The presented solution was simulated in RobotStudio 2019 software, while calculations were performed in Maple 14 software. In addition, the correctness of the presented solutions was verified on a real object, an IRB 2400 robot equipped with a Keyence 2D scanner. [ABSTRACT FROM AUTHOR]

This article deals with the design and creation of digital twins of robotic stations. A literature review of digital twins, robot programming methods and laser tracker applications is presented. This paper shows that the construction of digital twins is closely related to one of the most popular methods of robot programming, i.e., off-line programming. In the case of digital twins of robotic stations, modeling accuracy and two-way communication with the real station proved to be crucial. The article proposes a methodology for solving the basic problem of off-line robot programming, i.e., the limited accuracy of the representation of the station and the details. The algorithm of proceeding in the case when the station already exists and its digital model is built and the case when the digital model is first created and the real solution is built on its basis is shown. According to the developed methodology, a digital twin of a real robotic station was created and the possibilities arising from the use of virtual tools were shown. The developed digital twin has the ability to communicate with advanced Matlab 2021-type tools, uses cloud solutions and virtual and augmented reality for training, simulates physical phenomena and provides the ability to accurately program robots off-line. [ABSTRACT FROM AUTHOR]

The aim of this paper is to present examples and original solutions related to the application of the digital twin concept in designing safety systems for robotic stations. This paper includes a review of publications on robot safety systems and digital twins. Based on this review, it was concluded that further work in this area is justified. This paper demonstrates the use of a digital model of a robotic casting mold preparation station to design safety components for an industrial cell. A key element of this paper is the presentation of developed algorithms and their applications in building digital twins of existing robotic stations. By characterizing advanced safety systems used in robotic stations, an example of using a digital twin of a robotic station to create safety zones and so-called restricted zones for the robot was developed. As part of the research conducted, a real, comprehensive example of creating safety zones based on the robot's TCP paths was carried out. [ABSTRACT FROM AUTHOR]

Aircraft engine blades are produced through various techniques, one of which is precise electrochemical machining (ECM), commonly applied in the aerospace, automotive, and electromechanical industries. This method achieves machining accuracy ranging from 0.1 to 0.3 mm. However, components with complex shapes still require grinding and polishing. During the grinding of aircraft blades, achieving high precision and maintaining strict dimensional control are essential. This involves monitoring the thickness of the blade at key cross-sections, as well as the radii of the leading and trailing edges, chord lengths, twist angles, and more. The paper introduces a developed robotic blade grinding process featuring iterative laser measurement of geometric parameters. A custom measuring device with laser heads was designed, calibrated, and tested for repeatability. The measurement data were then used to determine the blade feed rate and machining path via a fuzzy logic decision system. The proposed method was validated on a series of PT6 aircraft engine blades in collaboration with Pratt and Whitney Rzeszów. [ABSTRACT FROM AUTHOR]

This paper presents a robotic test stand for the ultrasonic transmission tomography (UTT) inspection of stator vane thickness. The article presents the method of the test stand design in Autodesk Robot Structural Analysis Professional 2013 software suite. The performance of the designed test stand solution was simulated in the RobotStudio software suite. The operating principle of the test stand measurement system is presented with a specific focus on the measurement strategy. The results of actual wall thickness measurements performed on stator vanes are presented.

The article concerns the possibility of the automation and robotization of the process of deburring jet engine components. The paper presents the construction of a laboratory stand enabling the automation of selected production operations of typical low-pressure turbine blades. The work identifies important parameters and results of the technological process related to the removal of burrs that affect the exactness of the process. The results of the analysis of the impact of individual process parameters on the magnitude of forces and moments occurring during deburring were carried out and presented. The results of initial and detailed tests were presented. Based on the results obtained, it was noticed that doubling the rotational speed of the brush results in a linear increase in torque and an increase in the engagement of the detail in the disc brush, leading to a non-linear increase in torque. It has also been shown that with tool wear, the value of the torque generated by the rotating tool decreases. Based on the results of a comparison of manual and automated process and histogram analysis, results from an automated stand are centered more correctly inside of the required radius range. This means that the repeatability of the process is higher for an automated test stand, which is one of the key aspects of large-scale aviation component manufacturing. Additionally, it was confirmed by visual inspection that all burs had been removed correctly—the deburring operation for all tested work pieces was successful. Based on the results obtained, it was proven that introduction of an automated stand can improve working conditions (by the elimination of the progressive fatigue of employees and the possibility for injury) and allows for the elimination of the negative impact of the machining process on workers. Further areas in which the optimization of the process parameters of the edge deburring can be developed in order to reduce unit costs have also been indicated. [ABSTRACT FROM AUTHOR]

In this article, innovative approaches to realization of the wheeled mobile robots and manipulator tracking are presented. Conceptions include application of the neural-fuzzy systems to compensation of the controlled system’s nonlinearities in the tracking control task. Proposed control algorithms work on-line, contain structure, that adapt to the changeable work conditions of the controlled systems, and do not require the preliminary learning. The algorithm was verification on the real object which was a Scorbot - ER 4pc robotic manipulator and a Pioneer - 2DX mobile robot.

The paper presents methods used to determine the parameters necessary to build a mathematical model of an underwater robot with a crawler drive. The parameters present in the dynamics equation will be determined by means of advanced mechatronic design tools, including: CAD/CAE software andMES modules. The virtual prototyping process is described as well as the various possible uses (design adaptability) depending on the optional accessories added to the vehicle. A mathematical model is presented to show the kinematics and dynamics of the underwater crawler robot, essential for the design stage.

The article presents the issue of calibration and verification of an original module, which is a part of the robotic turbojet engines elements processing station. The task of the module is to measure turbojet engine compressor blades geometric parameters. These type of devices are used in the automotive and the machine industry, but here we present their application in the aviation industry. The article presents the idea of the module, operation algorithm and communication structure with elements of a robot station. The module uses Keyence GT2-A32 contact sensors. The presented information has an application nature. Functioning of the module and the developed algorithm has been tested, the obtained results are satisfactory and ensure sufficient process accuracy. Other station elements include a robot with force control, elements connected to grinding such as electrospindles, and security systems. [ABSTRACT FROM AUTHOR]

The robotic test stations of the considered design, operated at industrial plants, must first perform the processes and tasks they have been intended for as required by manufacturing cost reduction. It is important that these processes are completed at minimum power consumption. The paper presents the process of system parameter selection for minimised power consumption with the example of an actual robotic test stand built for manufacturing quality control of stators. The developed solutions were tested on a real-life object and deployed on the measurement test stand. [ABSTRACT FROM AUTHOR]

This paper presents an approach to modeling the slippage of a robot's rubber tracks moving on a non-deformable surface. A single horizontal deflection of a one-track lug is considered. The issue is modeled by FEM and verified by track lug deflection measurement and trajectory motion analysis. As a measurement device, a vision system is developed and configured. The vision-based measurement method can be considered as a new approach for estimating a robot's track slippage. [ABSTRACT FROM AUTHOR]