6-DoF Robot Base Positioning Methodology in Manufacturing Cells Using Inverse Reachability (ARBP-IR)

6-DoF robots are essential in factory automation, but determining their optimal base position relies on user intuition, making the process time-consuming, error-prone, and skill-dependent. There are discrete event simulation programs (DES) that support the shop floor layout design. However, DES often lack automated base positioning functions for industrial robots. This article presents a method for automated base placement of 6-DoF robots to reduce the effort for their implementation in manufacturing cells, specifically in automated layout creation of forging cells and processes. Forging cells present specific challenges, primarily due to the immobility of their components, which cannot be rearranged because of their significant mass. Given their long operational lifespans traditional forges are not inherently designed to integrate robotic systems. To address these challenges, an extensive literature review was conducted to assess the current state of automated robot base positioning methodologies. Although several methods and approaches exist, none sufficiently meet the needs of industrial applications within forging cells, as many originate from domains such as service or mobile robotics. The most promising methods were subsequently selected, merged, and refined to tailor them for the specific context of forging cell automation using industrial robots. The resulting positioning methodology is based on the principle of inverse reachability and has been implemented within the Visual Components software environment. Evaluation of the developed algorithm demonstrates a significant reduction in the time required to identify suitable base positions for complex cell design tasks.