Around two million new industrial robots will be installed in factories worldwide between 2020 and 2022. This is a forecast by the International Federation of Robotics (IFR). And the next generation of the "robot colleague" is already in the starting blocks: smarter, more intelligent, easier to operate. Precision is required when setting up and operating robots in order to avoid cost-intensive downtimes. Robot simulation tools ensure planning reliability and product quality. Dualis offers a solution for simulation-based offline programming of robot cells.

Dualis is a distributor of the 3D simulation platform Visual Components in Germany and develops add-ons and services related to the platform. Visual Components is used to plan and simulate manufacturing systems and production lines, including the corresponding robots.

Offline programming of robot cells with the Delfoi add-on
With the Delfoi add-ons, which are based on Visual Components, Dualis offers a solution for simulation-based offline programming of robot cells. The Delfoi Robotics Offline Programming Software (OLP) is designed to enable quick and easy programming, as well as path and program editing with numerous functions for the user, without requiring any programming knowledge.

According to the company, the use of the solution results in cost and time savings for programming and adapting the robot cells when changing components. Precise and flowing paths ensure quality control. The tool also offers calibration tools for precise tool paths and path management. All common robot brands are supported. The platform enables the CAD import of all components. Additional functions such as jigless welding with several cooperating robots are also available.

Increase safety and avoid downtime
"The advantages of offline programming are manifold. Today, there are often smaller batch sizes and more customer-specific products, which increases the programming rate. This favors more frequent production downtimes. Robot utilization is low, but should ideally be over 95 percent. In many industries, online programming can trigger high levels of downtime," explains Heike Wilson, Managing Director of Dualis.

By using offline programming systems, such as the Delfoi solution, the number of additional component buffers required or the use of additional robots can be reduced due to the higher availability of the robots. This reduces the capital expenditure of the production system and increases value-adding production even with small batch sizes.

With the 3D simulation solution and the Dualis add-ons, the user can easily implement the evaluation before the practical use of robots as well as the optimization of processes and machines during operation. This can be crucial to success, particularly in the networked factory of the future, where new processes and systems are often used.

Delfoi is planning to expand the offline programming solution to include automatic path planning and automatic solving of interference-free tool paths. There will also be features to prevent collisions, joint violations and speed or acceleration violations. as