Pairing Tecnomatix Process Simulate, provided by Siemens, with RTR’s RapidPlan* will empower users with the ability to generate collision-free paths created by RapidPlan. These paths can then be simulated and recorded within Process Simulate, subsequently deployed to the robots on the shop floor. This integration significantly alleviates customers' challenges when implementing industrial robots, enhancing productivity, and maximizing the benefits of robotics. The solution is straightforward: The user defines paths as a list of process points, RTR identifies collision-free routes between these process points, and generates a new path that incorporates the necessary waypoints and interlocks for collision-free operation of the cell. This video shows an end-to-end example of the RTR Plugin use.

*RapidPlan is the name of RTR’s software product.

• Intel CPU with 8 cores / 16 logical processors, or more

• Workstation-class Nvidia RTX or newer GPU with 4GB graphics memory, or more

• 64GB RAM for a work cell project with 4 robots or less. 128GB RAM is recommended for large work cells (with up to 16 robots)

• Enough space in the disk. RapidPlan projects require several GB of space in disk, up to 20GB in big cells. We recommend 1TB of space in disk.

The Tecnomatix Process Simulate installation does not require any additional step. The RapidPlan Plug-in will be installed with the standard distribution. The feature can be enabled through the corresponding license.

In addition to the plug-in in Siemens PS, users need to install the RapidPlan software. There are 2 ways of installing RapidPlan:

• Standalone: Installing both Siemens PS and RapidPlan in the same computer. https://realtimerobotics.atlassian.net/wiki/spaces/TPS/pages/2704310343/Installation+guidelines+for+customers#Standalone

• Server-Client: Installing Siemens PS in one machine (client), and RapidPlan in a different machine (server). Multiple clients can reach the server in this configuration, only one at a time. https://realtimerobotics.atlassian.net/wiki/spaces/TPS/pages/2704310343/Installation+guidelines+for+customers#Server%2FClient

The RapidPlan Plug-in is installed by default in Siemens PS after the version 2301. However, you will need an additional software package which installs the RapidPlan software. The package can be downloaded from the Siemens GTAC site, under “Additional Downloads” in the Tecnomatix download page.

Yes, you will need an additional license to use the RTR plug-in. Only one license is required, and it applies only to the Tecnomatix PS side - RapidPlan is licensed over the interface. The license is provided directly by Siemens, contact your Siemens representative for more information.

The RTR software (RapidPlan) supports point-to-point applications (spot welding, riveting, inspection). Handling applications are not fully supported, but can work with workarounds. The reason to this is that Siemens PS does not communicate to RapidPlan if the robot is holding the part or not, and the status of the jig and clamps.

Path applications, like dispensing, arc welding, or roller hemming are not supported.

Yes, both linear rails and weld guns are supported. These axes must be configured as additional axes within the robot controller. The user is responsible for specifying the positions of the external axes at the process points, while RTR will determine the positions of these axes within the waypoints.

RapidPlan does not support all kind of weld gun kinematics yet. Certain guns, like X-type guns may have what we called a kinematic loop, which is not supported. In this case, Siemens PS will export the gun as a static obstacle, in which case RapidPlan will not be able to open or close the gun. The gun will be exported in the current opening state. If the gun movement is necessary, the user will have to modify the gun kinematics to a different one that does not have kinematic loops

During the export phase, RapidPlan can fail to generate collision-free paths, returning an error. These are the most common errors:

TARGETS ARE HARD TO REACH

Reason: RapidPlan could not connect the targets in the allocated time. Either the targets cannot be connected, or RapidPlan needs more time to calculate.

Solution: Increase segment time in the export window.

TIP: RapidPlan does not use all the allocated time, therefore increasing the time from 100s to 3000s will not necessarily take 30x more time. The extra time will be used where it is needed until the solution is reached. At RTR, we run a first pass at 100s, then use the max. segment time allowed for optimal results.

INVALID LINEAR CONNECTIONS

Reason: in the exported paths in Siemens PS, some points are marked as LIN. The export is built so that, when a target has the type LIN, RapidPlan does not try to do any motion planning, it just connects the previous point and the one with LIN with a direct cartesian connection (linear). If this connection has a collision, the software returns this error.

Solution: There are two ways of solving this:

• If it is required that the process points are reached with type LIN, then an approach target of type PTP before each process point must be added. The approach target can be located at the same location than the process point, or a bit moved. (Fig PTP-LIN)

• Otherwise, the solution is to change all process points to PTP, and let RapidPlan find solutions in joint space. (Fig PTP)

CONVERTER SHUTDOWN

Reason: RapidPlan has utilized all the RAM memory available. When installed under Windows WSL2, RapidPlan can only access 50% of the RAM available, by default. RTR recommends using PCs with 128GB RAM when installing RapidPlan in WLS2, ensuring that RapidPlan has access to at least 64GB of RAM.

Solution: The first solution here is to use a computer with more RAM, or extend the RAM of the current computer. A second solution would be to extend the RAM allocated to RapidPlan in WSL2 above the 50%, this makes sense when the computer has at least 64GB of RAM in total, contact Realtime if this is your case. The last option would be to install RapidPlan in a separate computer with enough resources, in native Ubuntu (see https://realtimerobotics.atlassian.net/wiki/spaces/TPS/pages/2704310343/Installation+guidelines+for+customers#Server%2FClient)

TARGETS NOT REACHABLE

Reason: some of the targets are not reachable for RTR. This could happen if the collision rules are not defined, since otherwise Siemens PS checks all targets for reachability

Solution: Check that all targets are reachable collision-free. Add collision sets to avoid this error in the future.

During the connection phase, there are multiple reasons why an error could happen:

ERRO 2022 - COMMUNICATION SIEMENS PS ↔︎ RAPIDPLAN IS BEING BLOCKED

Reason: the firewall or any other protection software is blocking the communications between Siemens PS and RapidPlan.

Solution: make sure the firewall rules allow the communication between the two software modules. Ask your IT department for support.

Configure Windows Firewall

The connection between Process Simulate and the robots in the Control Panel can be blocked by the Windows Firewall and will in that case cause an error 2022 to occur.

To allow Process Simulate through the Firewall, go to Windows > Control Panel > System and Security > Windows Defender Firewall > Allowed apps and allow every instance of Tecnomatix through the used network type:

Image Added

Press OK and then restart Process Simulate for the changes to take effect.

ERROR 4023 - MULTI ROBOT PLAN FAILURE

Reason: the system run into a deadlock (robots block each other and cannot continue). RapidPlan tried to resolve the deadlock but couldn’t

Solution: select an alternate location for the robots to use in case of a deadlock. Link to documentation

The RTR plugin only does motion planning. Changing the order and allocation of targets and the robot configuration and position is considered cell optimization. Realtime Robotics is capable of optimizing these parameters, but this is currently outside of the scope of the plug-in. For more information about Optimization, please contact Realtime Robotics.

Realtime Robotics has developed algorithms that provide cell optimization for cycle time as follow:

Optimization

User input

• List of targets and robots

• Constraints (What is allowed?)

Tool output

• Optimized target sequencing

• Optimized Target allocation

• Optimized Tool rotation and robot configuration

• Collision-free paths 

• Interlocks

Optimization is currently available as a service. Contact Realtime Robotics for more information about cycle time robotic cell optimization.

The interlock generation is a feature that is in beta state. If you are interested in testing this feature, please contact Realtime Robotics or your Siemens representative to enable the feature.

Currently, the path recorder only generates locations, without any parameters. Siemens and RTR are working to have the parameters added automatically.