Toolpath postprocessing for three axes milling in redundant robotic workcells by means of fuzzy integration in a cam platform

Nowadays, the use of kinematically redundant robotic workcells for machining tasks is increasing. It is due to their capacity to avoid singular configurations, although a choice among a set of possible configurations is required. Experience and knowledge of the workman in charge of the manufacturing process allow carrying out an efficient control of the movement in these cases. However, it is a tedious job. This article presents an effective implementation of a CAM-robotics integrated fuzzy postprocessor based on the position analysis. It is focused on a workcell consisting of one robotic manipulator (KUKA KR15/2 with 6 rotary joints) mounted on a linear axis and synchronized with a rotary table. After the implementation of the inverse kinematics position analysis, a stand-alone fuzzy controller has been programmed with Matlab´s fuzzy logic toolbox (The MathWorks, Inc.). Two C++ programs complement the translation of toolpath position information from the NX-CAM platform (NXtrade-Siemens Corp.) into KRL (KUKA robot language), in order to adequate the location of the robot and the workpiece in the execution of the task and avoiding singularities or joint limits. This article solves the problem for a constant tool orientation milling process and sets the technological basis for future research at five axis milling operations.