Cutting Small Circles: A Touchstone for Robotic Precision
2024-08-20
Cut into small circles—experts call this the touchstone of robotic precision.
Among the many challenging industrial applications, using lasers to cut perfectly small circles has always served as an ultimate test of industrial robots’ trajectory accuracy and control capabilities. The smaller the diameter of the circle, the higher the demands placed on the robot’s precise positioning and trajectory-tracking abilities. For this very reason, in industries such as automotive component manufacturing—where precision requirements are exceptionally high—the application of laser-cut small circles has long been regarded by international robotics brands as a sacred domain, off-limits to all but the most exclusive players. Among them, S, a high-end industrial robotics brand headquartered in Switzerland, has maintained a long-standing, unrivaled leadership position in this field.
However, as the pace of high-level domestic substitution accelerates, STEP—a company that masters core robotic technologies—has, after years of practical exploration and through innovative algorithms and optimized mechanical designs, significantly enhanced the precision and rigidity required for cutting small circles, thereby breaking through this technological bottleneck in one fell swoop.
01 The Industrial Robot’s “Ultimate Dance”
Through innovative algorithms, STEP has significantly improved both absolute positioning accuracy and pose-changing positioning accuracy at fixed points. The small-circle accuracy can reach as high as 0.15 mm, and the joint position error is as low as 0.03°. How has STEP achieved this? Let’s continue reading to find out.
02 Endowing robots with “precise eyes”
/Error Modeling and Absolute Accuracy Compensation Technology/
Relying on its independently developed full-parameter laser calibration software and high-precision laser trackers, STEP has achieved precise measurement of industrial robot link parameters, reduction ratios, joint flexibility, and other key parameters. Combined with cutting-edge error modeling and absolute accuracy compensation technologies, it has enabled highly accurate positioning of the robot’s end-effector.
/Self-learning Backward Gap Hysteresis Compensation Technology/
Reverse hysteresis is a common phenomenon in mechanical systems and one of the key factors affecting the accuracy of robotic trajectories.
To address this issue, STEP has developed a self-learning compensation technology for backlash hysteresis. This technology can automatically detect and compensate for errors that occur during the robot’s reverse motion, eliminating the hysteresis associated with gear back-driving and ensuring smooth and accurate robot movement. At the same time, based on actual machining results, the system automatically adjusts the compensation parameters to achieve optimal compensation performance.
/Optimize structural design/
Through joint static and dynamic simulations of robots, STEP adjusts the inertia distribution across each robot joint and continuously optimizes the structural design of the robot’s body, thereby achieving both lightweight construction and high cycle rates. Based on a parameter-design approach that incorporates multiple constraints—such as constraints on robot joint torques and lifetime constraints for key components—STEP has significantly enhanced the robot’s mechanical rigidity and service life, laying a solid foundation for the robot to perform highly precise operations.
Now, let’s take a look at a comparison chart of finite element simulations for the casting before and after optimization:
After simulation calculations, the peak stress in the improved casting is approximately 40% of the peak stress in the original casting.
Through relentless refinement and constant innovation, STEP Robotics has forged a sharp edge and broken free from conventional constraints to usher in a new chapter. By continuously driving technological innovation and maintaining stringent quality control, STEP Robotics has achieved industry-leading precision in trajectory accuracy, delivering users more precise and reliable automation solutions.
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market@stepelectric.com
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No. 1560, Siyi Road, Jiading District, Shanghai Municipality