Pre-Processing Optimisation of Robot Control to Reduce Energy Consumption

The huge growth in the utilisation of six-axis robots in various technological applications in production calls for a detailed focus on the process of preparing Numerical Control (NC) programmes for effective robot control. Considerable attention is currently being paid to optimisation by increasing stiffness, but there is also a need to focus on reducing energy consumption in robot control. Focusing on reducing energy consumption is highly justified given the widespread adoption of robotic systems across diverse manufacturing technologies and the significant potential for application. This is particularly relevant today, when minimising production costs is a critical industrial objective. A redundant degree of freedom—which is the possibility to rotate around the end-effector axis and thus influence the adjustment of the rotation of the individual robot joints—can be used for this purpose. Therefore, this paper exploits this redundant degree of freedom to set up a proper robot configuration that reduces energy consumption. The user-friendly solution, including the algorithm design and processing through a function, could be effectively implemented within an industry-standard post-processor solution for generating NC programmes for robots. This solution is unique as it is used for the optimisation of the working section of the toolpaths, where continuous control of the end-effector movement during manufacturing operations occurs. The solution was verified on a KUKA KR60 HA robot; however, it is applicable to any industrial six-axis robot. Substantial energy savings were obtained in multi-axis toolpath operations, with a 7.5% reduction in total energy consumption when using the optimised NC programme.