Offline Programming

1.Definition & Core Concept
Offline Programming (OLP) refers to the process of designing, simulating, and optimizing robotic tasks in a virtual environment without interrupting physical production lines. By integrating CAD/CAM data and physics-based simulation tools, engineers can pre-program robots for tasks like welding, cutting, assembly, and inspection.
2.Technical Workflow
Model Import: Load 3D CAD models of workpieces, tools, and production environments into OLP software.
Path Planning: Define robot trajectories using collision-free algorithms and kinematic/dynamic models.
Simulation & Validation: Test programs in a digital twin to check for errors.
Code Generation: Convert optimized paths into robot-specific instructions.
3.Key Technologies
CAD/CAM Integration: Directly extract geometric constraints from CAD files for precise path generatio.
Collision Detection: Algorithms to avoid physical clashes between robots, tools, and fixtures.
Post-Processing: Adapt generic code to specific robot controllers .
Digital Twin: Real-time synchronization between virtual and physical systems for adaptive control.
4.Applications in Mechanical Industry
Complex Welding: Program multi-axis robots for aerospace components with irregular geometries.
High-Precision Machining: Generate toolpaths for CNC milling or laser cutting with micron-level accuracy.
Automated Assembly: Plan sequences for inserting gears, fastening screws, or aligning parts in automotive production.
Quality Inspection: Pre-program CMMs (Coordinate Measuring Machines) to scan critical dimensions.
5.Advantages
Zero Downtime: Programs are developed offline, eliminating production pauses.
Multi-Robot Coordination: Synchronize tasks for collaborative robots (cobots) in shared workspaces.
Cost Efficiency: Reduce material waste (e.g., optimal sheet metal nesting) and energy consumption.
The main features of Visual Components simulation software include:
Discrete Logistics Simulation: Users can easily import existing models, make necessary edits and optimisations, and quickly put them into use, greatly reducing project preparation time. Robot Offline Programming: Supports the simulation of the operation process of robots and their workcells, assesses productivity and safety, and accelerates the design and deployment of automated production lines. PLC virtual debugging: supports online verification and debugging of PLC programs to ensure accurate control logic and real-time data interaction with the simulation environment.
Calibration points are machined on the machine to ensure the accuracy of the installation, and the software mechanically compensates the machine to minimize errors between the machine and the digital model
Customize the software post-processor according to the conditions of use and needs of different users.
Adjustment of welding current, voltage, and speed through Metalleco's welding expert database for multi-layer, multi-pass welding of medium and thick plates.
Welding Automation
Using CAD-integrated OLP systems like Delfoi Robotics, engineers design welding paths in virtual environments, optimizing parameters such as torch angles, motion trajectories, and welding speeds without interrupting production lines. This approach improves welding quality and reduces cycle times in automotive and aerospace manufacturing.
Laser Cutting and Material Processing
OLP software generates complex cutting paths by analyzing 3D models of components, ensuring high precision in tasks like sheet metal fabrication. For instance, FANUC’s ROBOGUIDE simulates laser cutting processes, detects collisions, and exports error-free code to physical robots, enhancing material utilization and reducing waste
Robotic Grinding and Polishing
Offline programming enables trajectory planning for surface finishing applications. Research demonstrates its use in abrasive belt grinding for curved components, where OLP systems calculate optimal contact forces and tool orientations based on CAD data, ensuring uniform surface quality
Assembly and Inspection
In precision assembly, tools like iRobotCAM extract geometric constraints from CAD models to automate robot trajectories for part fitting and screw fastening. Similarly, OLP supports 3D coordinate measurement systems (CMMs) for pre-programming inspection routines, reducing setup time and human error in quality control
Palletizing and Logistics
OLP simplifies path planning for palletizing robots in warehouses. By simulating stacking patterns and collision-free motions, systems like FANUC’s PALLETIZING module ensure efficient load distribution and adapt to dynamic logistics demands