Tormach is advancing automation by integrating LiDAR technology into PathPilot® Robot Edition, designed to simplify and enhance pick-and-place operations with the ZA6 industrial robot and the 1500MX CNC mill. This update enables the robot to scan the parts area with a LiDAR sensor, removing the need for time-consuming and error-prone grid placement. Let’s explore how Tormach’s use of LiDAR technology improves flexible part placement, stacking, and the overall user experience in automation.
What is LiDAR and How Does It Work?
LiDAR, or Light Detection and Ranging, is a technology that uses laser pulses to measure distances. Each pulse is sent out from a laser and bounces back to a sensor, which calculates the distance based on the time it takes for the light to return. While LiDAR is commonly used in mapping, autonomous vehicles, and even some smartphones, Tormach is leveraging its accuracy for CNC machining automation. By employing LiDAR, the ZA6 robot can detect an object’s precise position and orientation, as well as its height — enabling part stacking and automated adjustments that a traditional camera setup simply can’t provide.
Benefits of LiDAR Over Traditional Camera Systems
Previously, pick-and-place operations relied on parts being arranged in a fixed grid pattern. However, such systems come with limitations. The robot needs to know exactly where each part is positioned, which means that if anything shifts, the setup can become inaccurate, increasing the risk of crashes. Here are some significant benefits LiDAR offers:
— Automatic Position Calibration: The LiDAR scanner continuously scans and recalibrates, ensuring the robot can detect any shifts or misplacements in real time. This eliminates the need for fixed grid setups and minimizes the likelihood of crashes.
— Stacking Capabilities: Unlike cameras, LiDAR detects height, allowing for efficient part stacking. This ability makes it an excellent tool for compact spaces and projects requiring layered storage of parts, something traditional cameras cannot achieve.
— Environment Mapping: With potential future developments, LiDAR could help the robot navigate its surroundings, allowing it to detect obstacles, such as machine enclosures or walls, and avoid collisions.
The ZA6 robot handles a workpiece using LiDAR scanning technology.
Behind the Scenes: Developing the LiDAR Algorithm
The LiDAR integration requires a sophisticated algorithm to translate raw data into actionable tasks for the ZA6 robot. Each scan generates a point cloud, representing the exact locations of objects within the robot’s reach. Here’s how the algorithm breaks down each task:
— Global Scan for Initial Data: The LiDAR sensor performs a global scan to identify any parts in the work area. This scan generates a broad map of the area, capturing the position and height of each object.
— Noise Filtering: The raw data from LiDAR often includes “noise” or stray reflections. The algorithm filters these out to isolate the most accurate points on each object, increasing the reliability of pick-and-place actions.
— Object Identification and Position Calculation: After noise filtering, the point cloud is clustered to recognize each individual part. A convex hull, essentially a simple shape, is created around each object to determine its orientation and center, so the ZA6 robot can grasp each piece accurately.
— Secondary Local Scan: A more detailed scan of each object ensures precision in positioning, minimizing errors during grasping. This double-checking process also includes a torque check to avoid collisions, which protects the robot and parts.
Tormach’s Plan for LiDAR Integration in PathPilot
The LiDAR-enabled PathPilot Robot Edition is currently being refined to support different part sizes, configurations, and stack heights. Tormach’s software engineers are working to streamline commands so users can easily set up complex automated operations without extensive coding. This update will allow users to set parameters like workpiece size, gripping orientation, and even initiate commands like “find and grasp object.”
For advanced users, Tormach is also developing an API that will offer deeper customization capabilities. From basic pick-and-place tasks to complex automation routines, users can tailor the ZA6’s functions to fit their needs.
Image of raw point cloud data from the LiDAR sensor on the ZA6 robot.
Moving Beyond Grids, Future Possibilities, and User Accessibility
The current LiDAR integration allows Tormach to bypass the grid-based setup traditionally used in robotic pick-and-place applications. This approach enhances flexibility, particularly for shops with multiple part sizes and irregular layouts. Additionally, the LiDAR-based scanning provides enhanced adaptability in resuming operations if interruptions occur — no need to reset to a specific grid position; the robot just scans, locates, and resumes.
Tormach’s ongoing goal is to make CNC automation more accessible. The PathPilot updates are designed to help users of all skill levels. With a conversational interface under development, users will soon be able to input part dimensions and other specifications directly without extensive coding, making automation accessible for shops of all sizes.
For those eager to explore LiDAR-based automation, the Tormach Forums provide a space to discuss early-access beta testing opportunities. This open-source approach to software improvement means users can help shape the features and functionality of Tormach’s PathPilot Robot Edition.
By leveraging LiDAR in PathPilot, Tormach is redefining how machine shops approach automation — moving from rigid grid systems to a more flexible, intuitive approach that enables easier handling, stacking, and part management.
