Design optimisation of industrial robots using the Modelica multi-physics modeling language

Superior performance of industrial robots can only be achieved if the interaction of mechanics, electronics and software is taken into account already in the design phase. Conventional approaches to modelling, however, cannot cope with such multi-physics systems. The new Modelica modelling language has been specifically developed for this purpose. It also significantly increases re-usability of model components, since components adapt to the connection structure in which they are used. In the European resarch project “Real-time Simulation for Design of Multi-physics Systems“ (RealSim), efficient tools for modelling, simulating and optimising industrial robots are developed. A general Modelica MultiBody library (freely available from [1] or [2]) formed the basis for the development of a specific robot component library. A development environment for creating robot models out of the available components was provided, in which initial calculations to verify the first rough design can also be performed. Tools for automated optimisation were developed that take the initial design as the starting point. Afterwards, the performance of a design can than be verified in a real-time simulation before investing in building a real prototype. These powerful development tools provide the basis for an even more efficient development process and superior robot performance in the future.