This simulation demonstrates the complete workflow of our PVC hot water coupling automation system using RoboDK, an industrial robot simulation software. The simulation includes the entire process from pipe detection to final placement, showcasing the precision movement and coordination of the robotic arm throughout the manufacturing cycle.

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Simulation Overview

The RoboDK simulation provides a comprehensive visualization of our automated PVC pipe coupling system, demonstrating how the UR10 robotic arm interacts with various components of the production environment. The simulation showcases:

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Simulation Components

Our RoboDK simulation includes the following components and elements:

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2D Mathematical Simulations

In addition to our 3D RoboDK simulations, we've developed 2D mathematical simulations to study specific aspects of the robotic system. These simulations focus on the mathematical principles behind robot arm kinematics and control, particularly highlighting singularities and movement patterns.

2D Coupling Process Simulation

Our 2D coupling process simulation provides a mathematical visualization of the entire PVC pipe coupling workflow using a simplified 2-joint robotic arm. This simulation demonstrates:

• Forward and Inverse Kinematics: Calculating joint angles to reach specific positions in the workspace
• Complete Process Flow: From pipe pickup through hot water bath to final placement in the mold
• Spatial Relationships: Showing the arrangement of key components (pipe supply, water bath, mold)

This simulation was implemented using Python with Matplotlib for animation and visualization, allowing us to test the basic movement patterns and process sequence before implementing them in the 3D environment.

Singularity Explorer

The Singularity Explorer is an educational tool we developed to demonstrate one of the key challenges in robotic manipulation: kinematic singularities. Singularities occur when certain joint configurations cause the robot to lose one or more degrees of freedom, making some movements impossible. This interactive simulation:

• Visualizes the Jacobian Matrix: Shows how this matrix relates joint velocities to end-effector velocities
• Demonstrates Singular Configurations: Highlights positions where the determinant of the Jacobian approaches zero
• Explains Movement Limitations: Shows how singularities restrict the robot's ability to move in certain directions
• Explores Workspace Boundaries: Maps the complete reachable area of the robotic arm

Understanding singularities is crucial for our PVC coupling automation, as they must be avoided during critical operations like pipe insertion into the mold. This simulation helped us develop path planning strategies that prevent problematic configurations.

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Simulation Implementation Details

The simulation was created using RoboDK industrial robot simulation software, which provides accurate modeling of robot kinematics, environments, and process workflows. Key aspects of the simulation include:

1. Robot Model: The simulation uses the Universal Robots UR10 model, a collaborative industrial robot with 6 degrees of freedom, ideal for the precise movements required in PVC pipe handling.
2. Custom Gripper Design: A specialized gripper was modeled to demonstrate the actual grasping mechanism designed for the PVC pipes.
3. Complete Workflow: The simulation demonstrates the entire process flow:
   • Detecting and picking pipes from the pallet
   • Transporting pipes to the hot water bath
   • Precise submersion and timing in the water bath
   • Transport to the molding station
   • Accurate placement in the mold
   • Return to home position for next cycle
4. Camera Integration: Two virtual cameras were integrated to simulate the vision system that detects pipe positions and validates proper placement.
5. Path Planning: Collision-free path planning between stations ensures safe and efficient movement of the robotic arm.

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Benefits of RoboDK Simulation

Using RoboDK for simulation before physical implementation offers several advantages:

• Risk Reduction: Validates the automation concept without the expense of physical prototyping
• Process Optimization: Allows for refinement of movement paths, timing, and station layout
• Training Tool: Serves as an educational resource for understanding the complete automation process
• Visualization: Provides stakeholders with a clear visualization of the proposed solution
• Coding: RoboDK helps us code robot-specific code for implementation on the actual hardware

This simulation represents a critical step in our development process, bridging the gap between theoretical design and physical implementation of the automated PVC hot water coupling system.