Simulation software aids design of robotic packaging systems

Visual Components' industrial simulation software is greatly assisting RTS Flexible Systems Ltd in the design and manufacture of the end-of-line, automated pick-and-place robotic systems for packaging operations. The simulation software is helping to optimise configurations before proposals are shown to potential customers and ensure that, once built, systems work 'right-first-time.'

Designed to increase capacity, enhance throughput and product yield, the innovative packaging machines feature an intelligent vision system developed by RTS Flexible Systems. The technology identifies products entering the packaging machine and is programmed to 'see' a variety of items that are either sub-standard or of a particular type for sorting and packaging. Appropriate positioning and feed rate data is sent by the vision system to multiple, downstream, four-axis fast picking robots that select and pick products from the conveyor belt for processing.

To ensure a design works to a customer's requirements, RTS Flexible Systems could either construct a machine and test various options to establish the best configuration, or build a virtual model and run a simulation at a fraction of the price. The company chose the latter approach, but the problem was finding the right software. RTS Flexible Systems already used several simulation systems; however, dsigned for specific purposes, these products all lacked the integration of statistics-based discrete event simulation and kinematic robot simulation.

Visual Components claims that it is unique in being able to offer this vital combination. Better still, the price is affordable and the open architecture includes an all-important application program interface (API). This enabled RTS Flexible Systems, with support from the software's UK distributor, SimX, a Manchester-based company specialising in factory and robotics simulation, to link the advanced programming in the manufacturer's machine vision system directly to the industrial simulation software.

Dr David Hopper, technical director of RTS Flexible Systems, states: "Using the combination of our technology and Visual Components we can optimise a system's configuration and performance, including how many robots are actually required. Now we can be sure at the initial design and proposal stage, whereas the alternative might be to discover - and to our cost - that another robot is needed, or one is redundant, only after the machine has been built and is in use. This has major benefits to us and our customers in minimising risk, saving money and enhancing our competitive edge."

What if...?

Besides preparing realistic and reliable sales proposals, the combined technology is also used to test 'what if' scenarios. Hopper says; "You can design for extremes, but in the real world it is the unexpected events that catch you out. With this system - which is unique in the world - we can run a wide variety of random tests to show customers how robust, flexible and efficient our solutions are.

"The highly realistic simulation achieved with Visual Components is also a good sales tool and facilitates requirements discussions with customers. What is more, we can also use the data for downstream manufacturing functions, so it is giving us tremendous value for money."