Process-based assembly planning using a simulation system with cell calibration

When using simulation systems in assembly planning, a considerable gap between simulated accuracy and real environment can often be detected. As an approach to bridge this gap, a cell calibration method based on measurements by a laser triangulation sensor is presented. The sensor system is mounted on an industrial robot and delivers the relevant data to the simulation system. Thus it is possible for the simulation system to calculate the change in position and orientation compared to the original model of the cell. This method eliminates the teaching effort that is required to adapt the simulation-based robot program to reality when using a conventional assembly planning method. Furthermore, it enables the user to derive the layout of assembly system directly from the process model with a high level of accuracy and to considerably reduce the time-to-market