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CSWIP - Certification Scheme for Welding and Inspection Personnel - BrainDump Information

Vendor Name : CSP
Exam Code : CSWIP
Exam Name : Certification Scheme for Welding and Inspection Personnel
Questions and Answers : 224 Q & A
Updated On : February 21, 2019
PDF Download Mirror : CSWIP Braindumps
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CSWIP exam Dumps Source : Certification Scheme for Welding and Inspection Personnel

Test Code : CSWIP
Test Name : Certification Scheme for Welding and Inspection Personnel
Vendor Name : CSP
Q&A : 224 Real Questions

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CSP Certification Scheme for Welding

New green Award Incentive issuer: Marichem Marigases | killexams.com Real Questions and Pass4sure dumps

assembly its goal to contribute to minimizing the environmental footprint of the maritime trade, Marichem Marigases has entered the network of eco-friendly Award incentive providers to aid quality ships demonstrating high environmental specifications. in view that the beginning of this year it has been the 2nd incentive company that joined the scheme that promotes the maximum specifications of excellent and defense within the waterborne transport.

Marichem Marigases will reward green Award certificates holders with extra discounts on the present cost record: a ten% discount on antipollution kits and machine and arc welding machines, and a 5% discount on the gas additives latitude of items and high pressure cleaning machines.

From left to right: Jan Fransen (govt Director, eco-friendly Award foundation), Dimitrios Mattheou (Chairman, eco-friendly Award foundation), Mr. Matthew greater (company executive, Marichem Marigases)

On the 25th of January, 2019, Captain Dimitrios Mattheou, chairman of the green Award basis, welcomed Marichem Marigases to the certification scheme. Handing over a symbolic plaque, he addressed the attendees by means of saying “clear air and seas as well because the welfare of people are the main areas to look after for each stakeholders of the transport industry. eco-friendly Award, as a physique-symbol of global environmental insurance plan and excellence, manages via its inspiring imaginative and prescient and strategic actions to motivate every stakeholder of the transport industry and obtain tremendous effects. we are very assured that Marichem Marigases will obviously reveal a commitment to attaining the green Award foundation’s ambitions, mission and vision with a different orientation on environmental excellence and safeguard in transport along with our well-liked incentive providers.”

Matthew more, business government of Marichem Marigases said.

“Marichem Marigases prides itself in merchandising environmental recognition; our participation within the green Award groundwork underlines our commitment to environmental insurance plan. The incentives provided can be found to ship owners and operators who're individuals of the green Award and may allow for a synchronized international response to toxins, highlighting each environmental and financial benefits, at the same time as promoting cognizance for a sustainable future.”supply: green Award foundation

Samsung trains feminine welders | killexams.com Real Questions and Pass4sure dumps

Samsung Heavy Industries (SHI) has knowledgeable one other set of  internationally-certified feminine welders in Nigeria.

The company is an incredible associate in the building of the Floating creation Storage and Offloading (FPSO) vessel for the creation of 200, 000 barrels of crude oil per day from the Egina deepwater container.

A beneficiary of the practicing scheme, Chinonye Okonkwo, advised The Nation that the practicing is enormously impactful as she grew to be some of the globally licensed welders in the nation.

She spoke of throughout the practicing, Samsung has brought out the welding knowledge in her, including that she has now develop into a home-grown engineeri in the oil and gas trade, including that she started in the administration department of Samsung Heavy Industries in Nigeria in 2015, and later moved into technical phase of the firm.

“I spoke to  my manager  on even if I could turn into a welder in Korea and he responded in affirmative that I may be trained as a welder in any part of the country. This caused me to apply for the working towards in Nigeria. within the starting, I confronted hurdles as many came around to peer no matter if i'd be successful or now not, however at last, I succeeded in being informed as a welder. according to her, she now trains others within the enviornment of welding, noting that the potential she received has helped plenty.

The practicing, she stated, has helped her to make a contribution her quota to the building of  Egina FPSO, which changed into partially fabricated in Lagos.

She entreated latest and prospective welders to take a cue from the trainees, including that there is splendor in being proficient as a globally licensed welder for the oil and gas and other industries.

Samsung, she pointed out, has self belief in Nigerian workers and firms, as a result of they meet their necessities.

“statistics were damaged all over building.  this is the first ever undertaking to meet Nigeria’s disturbing new requisites for “native content material”, which in essential terms means Nigerian-owned agencies offering work in Nigeria.  Over 9.7 million hours had been spent through the Nigerian workforce, with over 6,000 Nigerians in employment on the assignment at its top by way of Samsung and its partners and sub-contractors,” she brought.

career competencies present bridge to civilian life | killexams.com Real Questions and Pass4sure dumps


The profession talents program (CSP), also known as the DOD Skillbridge, offers U.S. carrier contributors the possibility to get a head birth within the civilian sector when the time comes to separate or retire from the military.

The software enables participants to plan ahead. although the software isn't an entitlement, it may also be a chance for contributors to get their foot in the door earlier than leaving the carrier.

The working towards all the way through this software can range in response to the goals of the provider member, however some regular paths consist of computer linked fields, manufacturing, medical or healthcare, precise estate and welding.

carrier participants should be beneath contract for 180 days and predict to be separated from carrier inside 180 days to participate in the CSP.  After commander approval, contributors may also birth an internship, apprenticeship, on the-job-practising or employment competencies training at an approved CSP employer as much as one hundred eighty days before separation or retirement.

“CSP gives provider individuals with the chance to participate in profession and ability practising classes throughout their transition duration, to enrich their employment possibility upon transition from active responsibility,” noted Chad Schwab, Langley training center profession skills software specialist.

The CSP gives 180 days highest to birth working for the company. however a carrier member can doubtlessly work below the company for that period of time, the provider is not obligated to employ them after the working towards length.

The criteria for accepted CSPs is listed below branch of defense guide 1322.29, Job practising, Employment knowledge working towards, Apprenticeships, and Internships (JTEST-AI) for Eligible provider individuals. This will be thoroughly vetted earlier than provider contributors start their skill training. each member taking this possibility should meet with a career skills specialist to discuss questions, issues and requirements.

“The CSP has two preferred end states,” spoke of Clayton Wilkes, profession competencies software installation administrator on the castle Eustis army training middle. “the primary is to give provider contributors with the chance to take part in career and talent working towards programs all over their transition.  The 2d aim is to enrich their employment probability upon transition from active obligation.”

Retired U.S. Air force master Sgt. Katie Ward observed she is aware of firsthand how the CSP can support the transition from militia to civilian existence.

“It made me believe more at ease and fewer uneasy with my transition,” Ward spoke of. “I’m so grateful i was able to beginning that subsequent chapter with such an in depth diploma of balance. The CSP offers you an skills you in any other case wouldn’t have if you go straight from your militia carrier into the job search.”

service members who're presently undergoing a clinical contrast Board can also begin a CSP eighty five days after their scientific retention decision aspect.

based on Schwab, considering the fact that the software is obtainable for transitioning provider members, the sooner a provider member begins making preparations for separation and transition into the civilian existence, the extra time commanders have to choose approval, which is according to the needs of the mission.

“Unit commanders have accountability to accomplish the mission, so if they can’t accomplish the mission on account of your absence, then they maintain the authority to deny CSP,” Schwab talked about.

For extra suggestions on the profession knowledge program at Langley name Chad Schwab at 757-225-3519 or for services at castle Eustis call Clayton Wilkes at 757-878-5356.

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Certification Scheme for Welding and Inspection Personnel

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All You Need To Know About AICIP And How They Certify | killexams.com real questions and Pass4sure dumps

If you are looking to certify your employees or even want to conduct an NDT, you must have basic knowledge about AICIP.

Image credit to: aicip.org.au

In the industry of welding and corrosion tests, NDT experts are an inevitable part. They provide certification to the various businesses to determine whether they can carry on with their welding works or not. But do you know that these personnel are further certified by AICIP?

So, what is AICIP exactly?

AICIP (Australian Institute for the Certification of Inspection Personnel) is a non profit certifying body that authorises various NDT experts to conduct inspection processes on different business grounds.

Does AICIP work with the joint accreditation system, Australian and New Zealand (JAS-ANZ)?

Well, this is still undecided whether they can work jointly or not. However, AICIP is following Standard AS ISO/IEC 170242004 Conformity assessment team which provides different general and intricate inspection certification under the National codes.

What types of plant and inspection personnel are likely to be covered by AICIP?

In general, AICIP certify design verifiers, welding fabrication inspectors and in-service inspectors. The types of plants that could be covered include, pressure equipment, amusement devices, lifts and pipelines. After certification, an AICIP pressure vessel inspector has the authority to conduct general to complex inspection process all over Melbourne.

What is the basic certification for a design verifier?

AICIP agreed with Engineers Australia that it should conduct the examinations for design verifiersand enlist successful candidates on its NER-3 register.

What is the basic certification for welding fabrication inspectors?

As per the agreement between AICIP and WTIA:

WTIA should introduce, administer and conduct the programs for welding fabrication inspectors. WTIA would link up with both AICIP and the International Institute of Welding (IIW) for both national and international recognition. In the case of national certification, AICIP would be responsible and in the international level, IIW. both of the certifying boards and welding/fabrication inspection programs give certification across the whole range of engineered plants.

How often will examinations be conducted and in what locations?

Examinations are held on a national basis in suitable venues and locations, at least twice a year. The number of locations depend on demand and the frequency will be at least six monthly intervals. Additional examinations could be conducted by AICIP personnel based on demand, in suitable locations and time.

Understanding the working procedure of AICIP and with whom they conduct the examination and certification is important. This is not only helpful for the business owners, but also for on-service welding personnel.

Did U.S. Army Officials Pocket Over $1 Million of Taxpayer Money? Exclusive Documents Reveal Investigation of 'Gross Mismanagement' Claims | killexams.com real questions and Pass4sure dumps

A U.S. State Department report out of Kiev, Ukraine, has accused officials at U.S. Army Europe of trying to cover up the “gross mismanagement” of more than $1.4 million in American taxpayer dollars.

Newsweek obtained a copy of a 31-page report containing allegations that officials at U.S. Army Europe intentionally concealed relevant information and lied to the U.S. Embassy’s financial office to have more than $1.4 million in foreign military funds distributed without official authorization in the fall of 2017. The report, written by the Embassy's chief financial officer, is marked “Sensitive, but Unclassified.” 

According to the document, the U.S. Embassy said that it had received paperwork to account for more than $3,300 but that more than $1.1 million appears to have been spent without documented authorization as of July 2018.

“By Embassy standards, the scope of the violation is quite large,” the report said.

An ongoing investigation is looking into the possibility that individuals within U.S. Army Europe pocketed the unauthorized taxpayer dollars, according to a Defense Department source with knowledge of the Pentagon probe. (You can read the full complaint to the inspector generals at the bottom of this article.)

Brad Moss, a Washington, D.C. attorney specializing in cases of national security, cited multiple issues after reviewing the complaint to the inspector generals. 

“This bureaucratic mismanagement raises several areas of concern, both as a financial matter and from a legal perspective,” Moss told Newsweek. “There is an obvious and immediate need to ascertain the scope of potential financial waste at issue and see if some—if not all—of it can be recouped.”

“That aside, there is a clear need to flesh out exactly who at U.S. Army Europe knew the details of the disbursements and the deficient documentation authorizing them at the time, as well as why these disbursements were permitted, given the flaws in the approval process," Moss added. “If anyone is deemed to have knowingly engaged in an effort to defraud the U.S. government, there are severe civil and criminal liabilities that could come into play.”

U.S. Army Europe disputed many of the allegations in the inspector general complaint. “We believe all outstanding ratification requests made by the Embassy were provided by U.S. Army Europe,” said Beth Clemons, a spokeswoman for the command.

The letter also details an alleged financial plot run by the Ukrainian government, saying officials submitted invoices to both the Canadians and the Americans for the same set of meals between July 1, 2016, and January 31, 2017. The complaint indicates that the scheme may have existed since the program’s inception back in 2015, resulting in hundreds of thousands of American tax dollars being wasted, according to the documents.

Separate from the alleged cover-up of unauthorized payments and the Ukrainian scheme, the report outlines how the lack of basic administrative and logistic controls over such items as food and fuel led to the likelihood that “a large sum of money was wasted in support of this program.” Contacted by Newsweek, a spokeswoman for U.S. Army Europe said they have no evidence anyone manipulated embassy staff, intentionally concealed relevant information or lied, and no evidence any U.S. government person or agency made improper payments.

The command added that they are not aware of any allegations or evidence that U.S. government personnel profited from unauthorized transactions. “We have no evidence of what the Canadians were charged or paid, we also have no evidence at this point of a ‘double-billing scheme,’” said the U.S. Army Europe spokeswoman. 

Newsweek contacted both the Department of National Defense in Canada and the Ministry of Defense in Ukraine seeking information, but no reply was returned before publication. The U.S. State Department did not reply to requests for comment for this story.

A State Department source at the U.S. Embassy in Kiev, who asked not to be named, told Newsweek that Dr. James Moyer, the comptroller at U.S. Army Europe, finally brought the U.S. Embassy the paperwork that his team had failed to complete on September 12, 2018, two months after the inspector general filing and more than a year after the financial office first sought clarification about the unauthorized payments. Newsweek was unable to reach Moyer for comment. 

All transactions in Ukraine are being reviewed by U.S. Army Europe to ensure there are no other outstanding transactions, said Clemons. The command said they believe the State Department referred the issue to the Pentagon's inspector general for review.

A Mission Expands and Spending Speeds Up

Russian_Ukraine_ArmyeuropeA Ukrainian serviceman fires his gun in the direction of Russia-backed separatists during night combat near the village Zaytseve not far from the the Gorlivka town late on June 20, 2018. More than 10,000 people have been killed in a simmering conflict between Ukrainian army and Russian-backed rebels in the country's east since the insurgency broke out in April 2014. ANATOLII STEPANOV/AFP/Getty Images

Four years ago, the Russian Federation thrust Ukraine into a Kremlin-manufactured shadow war between separatists that sided with Moscow and those aligning towards Europe and NATO after the annexation of Crimea by the Russian Federation.

A year and a half later, the U.S. State Department announced an expansion of U.S. European Command’s mission in Ukraine beyond the once-limited scope of training Interior Ministry national guard units.

Using Global Security Contingency Funds, a joint fund between the State and Defense Department, the Barack Obama administration sought to bolster Ukraine’s security by training the country’s regular army and special operation forces. Congress, however, wanted to provide a robust military aid package to arm Ukraine with mortar systems, ammunition, and the Javelin anti-tank missile.

The late Senator John McCain, the Arizona Republican who chaired the Senate Armed Services Committee at the time, dismissed Obama administration fears that sending lethal weapons would escalate the violence.

But the Obama administration’s viewpoint in Ukraine prevailed, and the U.S. opted to provide non-lethal aid such as tactical vehicles and night-vision capabilities. Canada provided similar assistance, sending thermal vision equipment and medical training.

While expressing some of the same concerns voiced during the Obama era, the Donald Trump administration has provided Javelins and other arms, a move that angered Moscow and deepened U.S. involvement.

But before the expansion, the U.S. Embassy’s finance office in Kiev began receiving payment requests from the Office of Defense Cooperation to support the Joint Military Training Group-Ukraine.

The payments would be in local Ukrainian hryvnia currency with U.S. European Command retaining administrative responsibility. Once the expansion took place, the funding for U.S.-backed Ukrainian programs switched to Title 22 Foreign Military Funds that are allocated to the State Department via Congress and often transferred to the Pentagon to execute security assistance programs.

Jeanie Clayton, a foreign service financial management officer for the U.S. Embassy in Ukraine, had grave concerns about how the Department of Defense processed large payments to support soldiers in both the U.S. and Ukrainian Army since she began her role in June 2017.

From a financial perspective, the embassy operates in a different commerce environment because the U.S. Disbursing Office did not have a local account to pay Ukrainian vendors providing services to U.S. European Command like food, Wi-Fi and laundry support. The Defense Finance and Accounting Service, the agency charged with the Pentagon’s finances, was not able to pay local vendors in Ukrainian currency.

So instead, the burden of bill-paying fell to the embassy’s finance office with the deputy chief of mission having to approve large payments associated with joint training programs under U.S. European Command.

Between 2015 and September 2017, the embassy processed more than $13.3 million in Acquisition Cross Support Services Agreement (ACSA) payments. ACSA agreements are inter-governmental activities that support military exercises between countries.

The letter to the inspector general states that the Office of Defense Cooperation did not consult with the embassy finance office to assess whether the office could support the payment responsibility.

“Rather, the invoices suddenly began to appear with no discussion or forewarning during the time period which embassy finance staff were overwhelmed with a dramatic increase in assistance funds and the overall growth of the mission,” Clayton wrote. The embassy staff were “stretched beyond capacity” and had “no ability to develop the expertise” to support the program from a financial standpoint.

“From the moment these invoices arrived, embassy staff were under enormous pressure to pay them immediately,” said a timeline of activity in the Embassy report obtained by Newsweek. An embassy Defense Department employee allegedly tipped off officials working at the Hetman Petro Sahaidachnyi National Ground Forces Academy in Livi, Ukraine, about the embassy’s finance office receiving the invoices.

This past January, Clayton was told that in the fall of 2017, she unknowingly disbursed several unauthorized payments totaling about $1.4 million in American taxpayer dollars to the Ukrainian Army Academy in support of the Joint Military Training Group-Ukraine where U.S. Army soldiers have supported joint military exercises for the past three years under an ACSA program.

She would later learn through an internal investigation conducted by her office that individuals within U.S. Army Europe’s G8 Tactical Support Division allegedly intended to conceal relevant information and lied to the financial office at the embassy. In the aftermath, officials at U.S. Army Europe reportedly tried to cover up the unauthorized payments by backdating fake documents before the service period, a claim the command disputes.

U.S. Army Europe said they were aware of the previous transaction issue, saying, “Once we discovered the issue, an AR 15-6 investigation was conducted. The investigation found that while administrative errors were made in the processing of payments for services, there was no indication that the payments were improper.

“As a result, the command took immediate action to remedy the situation by changing administrative procedures, personnel, and ratification processes,” said U.S. Army Europe spokeswoman Clemons. “The command is reviewing all past and present financial transactions in Ukraine to ensure the new implement payment processing procedures are effective.”

A U.S. Army official with knowledge of the feud between the U.S. Embassy and the command told Newsweek that they believe the invoice figures are correct and void of malicious wrongdoing; however, due to administrative discrepancies, U.S. Army Europe was never going to be able to produce documentation showing that the payments were legitimate.

A U.S. Army officer with knowledge of the allegations said that when the embassy would attempt to rectify the situation with the officials in U.S. Army Europe’s G-8, no one would pick up the phone. However, the source claimed Clayton inflated the perception of the problem to compel the Defense Department to take over the task of disbursing ACSA funds because the embassy's financial office is not equipped to handle the work. 

The Army source said the payments were mishandled on paper but not in practice. 

An Alleged Cover-Up

USEmbassy_KievA woman holds a placard reading 'Stop the creation of a new totalitarian empire' as she, together with other people, holds a huge Ukrainian and Crimean flags sewed together during an action in front of US embassy in Kiev on March 19, 2014. YURIY KIRNICHNY/AFP/Getty Images

On September 5, 2017, the U.S. embassy received several invoices about services in 2016 amid a “frenzy of year-end activity.” The invoices totaled over $1 million.

Embassy staff asked U.S. Army Europe why they were having to process payments more than a year after the invoices were issued, and why there were discrepancies between the memo showing the period of performance and the invoice documents.

Adam Perreault, a budget analyst with U.S. Army Europe’s G-8 section, told embassy staff that the Joint Military Training Group-Ukraine was sending their invoices in late and in February. His office was notified to stop making payments due to the double billing scheme theory. But, Perreault said, the financial scheme was investigated, and two weeks later, his office was told to resume payments.

The Inspector General complaint states that the response from Perreault appears to have been designed to manipulate the embassy financial office into making improper payments because he did not mention the unauthorized commitments.

In the ratification package documents obtained by Newsweek, Perreault writes that he discovered there was no service support agreement in December 2016—nine months before the email to embassy staff.

“Mr. Perreault’s explanation sounded plausible to me at the time, I now believe it was dishonest in two respects,” wrote Clayton.

The financial officer said U.S. Army Europe had an obligation to inform the embassy of unauthorized payments and that despite the May 2017 investigation, the double billing scheme was real, resulting in “hundreds of thousands of dollars of wasted funds,” according to Clayton’s complaint.

U.S. Army Europe confirmed that an investigation was conducted in May 2017, which recommended further action be taken to prevent future administrative errors and cited new remedy procedures that had already been implemented. The command said there was no evidence of a double-billing scheme.

At a meeting at the U.S. embassy on March 5, U.S. Army Colonel Paul Henry, the deputy G8, and William Pray, the budget management branch chief within the G8 Tactical Support Division, met with embassy staff to discuss the concerns over the unauthorized payments.

The meeting was attended by various representatives from the State Department; the Office of Defense Cooperation; and the 7th Army Training Command.

Clayton asked Pray to explain “how it was possible that the dates on the orders did not reveal the existence of the unauthorized commitments” between July 1, 2016, and January 31, 2017.

His response, she said, was, “That’s because they backdated them.” Clayton wrote in the documents that a standalone system generates ACSA orders and does not integrate with a separate system maintaining financial records, making it easy to falsify dates. 

As the meeting continued, Clayton told Pray that U.S. Army Europe G-8 has an ethical and legal responsibility to disclose all relevant facts to the embassy.

Pray is alleged to have replied that “laws were broken” and facts had been withheld from the embassy concerning official transactions.

U.S. Army Europe told Newsweek that neither Pray nor Henry recalls making such statements during the meeting and that they have no evidence anyone manipulated embassy staff, intentionally concealed relevant information or lied, and no evidence any U.S. government person or agency made improper payments.

Demystifying robot offline programming | killexams.com real questions and Pass4sure dumps

Cover Story: Software suppliers are disproving preconceptions about robot offline programming (OLP) being too complicated or not cost-effective. Several companies have developed software programs designed to make robots smarter, faster, and more flexible in a variety of challenging applications.

By Tanya M. Anandan February 5, 2019

Even though offline programming (OLP) has come a long way, misconceptions about it still linger. The old-school mindset that OLP for robots is not up to the task is one of skepticism. A lot of robot programming in the welding industry still is done manually, point by tedious point, with a teach pendant. Many still remember the old days of robotics that overpromised and under delivered. However, the dreamers and doers have been working to exceed expectations

Simulation and OLP software has evolved and become smarter, faster, more flexible, and reliable. This is a new era in ease of use and OLP software suppliers are here to demystify the softer side of robotics.

OLP vs. simulation

Most simulation and OLP solution providers will tell you it’s not one or the other. Simulation and OLP go hand in hand. Though the terms oftentimes are used interchangeably, there is a difference. You can have simulation without OLP but you cannot have OLP without simulation.

Robot simulation is the 3-D representation of a robotic cell or production line. It visually demonstrates how a robot moves along a path or trajectory from one XYZ coordinate to another XYZ coordinate. It can include multiple robots mounted on external axes working with multi-axis workpiece positioners, or coordinating on an assembly line. All this movement and planning, however, can get complicated.

Figure 1. Offline programming (OLP) software accurately simulates a robotic welding process using calibrated data for robot kinematics, external axes, and workpiece positioners. Courtesy: CENIT North America, Inc./Robotic Industries Association (RIA)

Figure 1. Offline programming (OLP) software accurately simulates a robotic welding process using calibrated data for robot kinematics, external axes, and workpiece positioners. Courtesy: CENIT North America, Inc./Robotic Industries Association (RIA)

“A lot of customers purchase a robot thinking it will behave like a computer numerical control (CNC). This is not the case,” said Albert Nubiola, CEO of RoboDK Inc. “CNCs are easy to program. The workspace is properly defined. It’s like a cube. However, robots have a spherical workspace, and because of joint limits and robot singularities (points at which a robot movement is not mathematically predictable), there are certain types of movements you cannot do. OLP helps avoid these errors when programming a robot.

In robotic machining, there could be hundreds to thousands of points,” Nubiola continued. “Nobody would ever be able to program that point by point using a teach pendant. You definitely need software to be able to do that offline.”

Simulation can be used for a proof of concept such as a robot integrator’s sales tool to demonstrate how a robotic system will perform. With simulation, users can detect possible collisions between the robot, tooling, fixtures and any safety fences. Simulation can analyze joint limits, singularities, and reach issues. Plus, it can reveal a host of eye-opening issues that save time and money in the long term.

OLP uses simulation to output robot-specific code that can be loaded onto the physical robot controller and then run the program. Post processors turn programming code into a language the robot can understand. Robot manufacturers have their own proprietary programming languages, which means third-party software solutions must be multilingual.

When OLP makes sense for a manufacturer

The main impetus for OLP is robot downtime, which is the time required to manually program a robot point by point with a teach pendant. There also are costs associated with the machine’s downtime and the programmer’s labor.

“If an end user is manually programming a robot on the teach pendant (online), they have to shut down production in order to program the part,” said Rob House, director of sales at OCTOPUZ Inc. “The benefit of using offline programming is you can be running production and you can program your next two, three, or five parts offline in the software and then once you’re ready to start a new job, you can just switch over the program and then start your production again.”

OLP is best-suited for complex path planning applications that require a lot of points such as welding, trimming, laser cutting, deburring, thermal spraying, painting, laser cladding, and additive manufacturing. OLP isn’t as beneficial for simple pick-and-place applications, assembly, packaging, and palletizing. These applications still can be programmed using offline software solutions, but users may not realize their return on investment (ROI). It’s more cost-effective to program manually if the process has only four or five points.

“If you’re spending as much time programming in software as you do with a teach pendant every single time you have a new part, you’re not any better off,” said Garen Cakmak, senior director at Hypertherm Robotic Software Inc. “For robots to be utilized in a high-mix, low-volume environment, software needs to be easy.”

Improving ease of use is top priority for these software developers. But simulation and OLP are pointless if they don’t accurately reflect reality.

Calibrate and don’t deviate

For OLP to work, the virtual world must match the real world. This means the simulation must represent the physical robotic cell accurately.

“The virtual environment in OLP software has to be an exact replication of the actual workcell on the shop floor, which is not the case in most situations,” said Helmut Ziewers, vice president of digital factory solutions for CENIT North America, Inc. “The deviations between a computer-aided design (CAD) model and the physical part associated with that CAD model can be minor or significant, especially in conjunction with less than perfect tooling. We still see major issues and people saying we can’t do this offline, because of those deviations.”

However, those deviations are not insurmountable. Calibration is critical.

“If we are off just a few millimeters or centimeters, you can create as many offline programs as you wish,” Ziewers said. “They will never fit. We have to know exactly how that robot was set up on the shop floor, and there must not be any deviations or else the OLP won’t work. The toolpath, the trajectory will always be off. This was the case with Crown.”

Crown Equipment Corporation manufactures powered forklift trucks for companies all over the world. Their Roding, Germany, facility has several complex robotic welding systems with external axes and multi-axis workpiece positioners. Faced with production bottlenecks caused by time-consuming manual robot programming, Crown Roding decided to explore if OLP was feasible. Their journey was not without a few hiccups. Some on the Crown team were skeptical while others were eager to try OLP.

CENIT was one of two suppliers brought into participate in a benchmarking study. Ziewers said they took CAD drawings provided by Crown’s automation integrator and created the virtual robotic workcell in their software. Based on those drawings, they created the robot program and ran it on the physical workcell. But something was off.

Figure 2. A robotic arc welding cell is programmed offline to reduce production bottlenecks caused by time-consuming manual robot programming. Courtesy: CENIT North America, Inc./Robotic Industries Association (RIA)

Figure 2. A robotic arc welding cell is programmed offline to reduce production bottlenecks caused by time-consuming manual robot programming. Courtesy: CENIT North America, Inc./Robotic Industries Association (RIA)

“The customer said this is exactly what we thought, offline programming is impossible. The last OLP software provider was not able to get it going and it looks like your software can’t do this either,” Ziewers said. “What they didn’t know is that the drawing from the integration company no longer matched how the integrator set up that cell.”

CENIT engineers arrived on site to physically calibrate Crown’s workcell.

“We found out what the differences were, dimensionally,” Ziewers said. “We applied those differences in our software and then adjusted the offline program based on the new setup in the virtual world. This matched exactly the physical setup from the shop floor, and the robot program worked perfectly.”

CENIT’s software coordinates the arc welding robot on an external axis with the movements of a multi-axis workpiece positioner. What used to take several days to manually program a part now takes a few hours. Production interruptions and downtime were reduced significantly and the welding quality consistently met the customers’ high standards.

Ziewers credited the calibration process for contributing to the application’s success. It’s important to consider the CAD model in relation to the physical part being processed.

“The part as it comes out of a press or die never has the same shape it’s supposed to have based on the 3-D CAD model. There’s always a difference between manufacturing and the CAD model. In sheet metal applications, for example, there’s springback.”

CENIT has calibration tools in their software such as three-point transformation, multipoint best-fit calibration, and in-process probing capability that help address issues related to springback and other variables that cause the physical part to differ from the CAD model. For example, the multipoint best-fit calibration tool picks 10 to 15 random points on a part and then feeds them back into the OLP system, which calibrates the part into the robot’s work envelope in the virtual cell.

“The ultimate goal of a 3-D simulation platform is to provide a software environment for the manufacturing automation controls engineer to validate their programmable logic controller (PLC), ladder logic, the human-machine interface (HMI) and OLP, and debug them in the virtual world before the actual workcell is built,” Ziewers said.

Easy to program; no expertise required

Another myth is that OLP is too complicated, difficult to use, and requires specialized expertise. Suppliers of simulation and OLP software are working hard to prove those assumptions wrong.

“People think that because a robot is a complex device, that offline programming is a complex tool as well,” Cakmak said. “That’s one of the biggest misconceptions. For people to adopt more robotics, we have to provide tools that make that end-user experience very easy and flexible at the same time.”

Hypertherm’s goal is to make robot programming as easy as possible for the user with their approach to simulation and OLP software.

Figure 3. A collaborative robot is programmed offline, saving operators months of manual programming time for this tedious railway maintenance process requiring hundreds of repetitive movements. Courtesy: Hypertherm Robotic Software Inc./Robotic Industries Association (RIA)

Figure 3. A collaborative robot is programmed offline, saving operators months of manual programming time for this tedious railway maintenance process requiring hundreds of repetitive movements. Courtesy: Hypertherm Robotic Software Inc./Robotic Industries Association (RIA)

“A welder is a process expert. He’s not necessarily a CAD/CAM programming expert, or a robotician,” Cakmak said. “Task-based programming takes away all that complexity of robot programming, the CAD/CAM and robotics expertise, and really empowers the process expert.”

Cakmak said the software reduces OLP time and effort by optimizing robot trajectories and by automatically resolving robotic errors and collisions. It works with a simple but powerful, intuitive user interface and includes tools to optimize part placement, tool tilting, and effective control of external axes. It allows the end user and integrator to maximize the robot’s capabilities.

In a case study, Hypertherm’s software took on a tedious process by programming hundreds of points for an application involving high-speed trains in northern Germany. If programmed manually, the process would have taken months, which is problematic because keeping up with rail maintenance is an ongoing issue for all worldwide rail and transport services. Added to that is the growing traffic problem due to the rising frequency of trains in the region. Rolling contact fatigue where the trains’ wheels meet the rails is a major issue.

To help remedy the signs of rail wear, German companies NSI CAD/CAM Technik and Mevert Maschinenbau collaboratively developed a rail milling technology designed to smooth and re-profile the rail surfaces. The reversible rail plates have to be turned almost daily or be replaced. Four maintenance workers used to do that manually, but now that process has been automated with a robot.

The robot unfastens and fastens dozens of threaded bolts on each rail plate. Programming the 720 start-up positions was done with OLP software.

“You have hundreds of holes that you have to go into with this robot,” Cakmak said. “Using our software (and a CAD model of the rail plate), you can very quickly program the process. It automatically detects the holes, creates the screwing cycle, takes the bolts and threads them into the correct locations, while always checking for robotic errors and collisions. It validates the process and then outputs an error-free robot program.”

Using OLP software allowed personnel to focus on other maintenance work, while the robot makes sure it doesn’t miss any bolts. Instead of the original four, only two maintenance workers are required for the robotic process, saving Mevert significant costs.

Figure 4. A robot unfastens and fastens hundreds of bolts in railway plates, a process made more efficient with OLP software. Courtesy: Hypertherm Robotic Software Inc./Robotic Industries Association (RIA)

Figure 4. A robot unfastens and fastens hundreds of bolts in railway plates, a process made more efficient with OLP software. Courtesy: Hypertherm Robotic Software Inc./Robotic Industries Association (RIA)

On the job is a collaborative robot. These power and force limiting robots allow operators to work in close proximity without the need for elaborate safety fencing. See below about how collaborative robots benefit from OLP.

High-mix low-volume no longer a constraint

Making OLP easier for users helps facilitate wider adoption of robotic processes. Robots are no longer the exclusive domain of megacorporations with deep pockets and high-volume production. Small and medium-sized enterprises (SMEs) can get in on the action. High-mix, low-volume production is no longer a constraint with simulation and OLP tools at the ready.

“We have some customers that have robot engineers who are running the robot and are very capable of programming it manually. They are also very capable with the software,” House said. “We have other companies that are just starting to automate. They don’t have a robot engineer on their staff. They can be hard to find and they can be expensive. They may be promoting a manual welder to now work with the robot and he may not have much experience.

“We take the approach that anyone should be able to program a robot,” House continued. “We have worked with people that have never touched a robot in their life and do not use software that often. It requires a little bit more training, but we can definitely get them to the point where they are comfortable programming a robot.”

Accumetal Manufacturing Inc. produces high-mix fabricated components for the off-road equipment industry, which includes subassemblies for mining equipment. The Canadian company has less than 100 employees and specializes in welding proficiency.

After many years of manually programming their robot, the volume of work increased to the level where Accumetal needed to take some pressure off their welders. They acquired a robotic welding cell and sought out a simulation and OLP software solution.

The cell consists of a six-axis welding robot and a single-axis headstock/tailstock workpiece positioner. House said this type of cell is very popular in the welding industry.

Figure 5. An arc welding cell uses OLP to help meet production demand by cutting programming time in half and reducing robot downtime. Courtesy: OCTOPUZ Inc./Robotic Industries Association (RIA)

Figure 5. An arc welding cell uses OLP to help meet production demand by cutting programming time in half and reducing robot downtime. Courtesy: OCTOPUZ Inc./Robotic Industries Association (RIA)

“Our software handles all seven axes easily,” House said. “We can either index the part in position and weld it, or we can support coordinated motion where the robot and positioner are moving at the same time.”

OCTOPUZ added support for Accumetal’s robots, which were developed by Panasonic. The software easily converts the programming code into Panasonic robot-specific code.

House said that was one of the benefits of their software. “You could be programming three different robots to do the same process and the software would convert it to each robot code.”

House said it also allows the user to grow with automation and become flexible. A company may be using the software for welding right now. If for example they want to do a trimming application in the future, they can use their same suite of software to program that application.

“It also allows them to work on more jobs,” House said. “Many companies will have a welding robot, but they are only comfortable running one or two parts on that robot. Everything else might be manually welded because they’re not sure the robot can handle it. But with offline programming, you can do things like R&D and testing to make sure you can weld a new part. You’re doing all this from the comfort of your office and your computer. This allows you to start opening new jobs for your robot.”

In addition to helping Accumetal reduce programming time, OCTOPUZ was able to help their customer reduce robot downtime and meet production demand. The customer reported their initial programming time was cut in half.

Figure 6. OLP software simulates all seven axes of this arc welding cell and optimizes the process with real-time seam tracking and one-click weld recipes. Courtesy: OCTOPUZ Inc./Robotic Industries Association (RIA)

Figure 6. OLP software simulates all seven axes of this arc welding cell and optimizes the process with real-time seam tracking and one-click weld recipes. Courtesy: OCTOPUZ Inc./Robotic Industries Association (RIA)

Accumetal’s cell also used through-arc seam tracking (TAST) for real-time tracking of the weld joint. This is used in case the robot needs to adjust its trajectory on the fly like when the CAD model and the actual part don’t match.

“We do a lot in the welding industry,” House said. “Welding is notorious for having parts that are not exact, especially for the CAD. There can be quite a bit of discrepancy. Lasers are very popular. You create a path in our software and then using a laser seam tracker, if the part is not perfect, it will modify our path to follow that seam. Same thing with touch sensing. The robot will touch the welding wire to the part at different positions to locate that part. Then, based on any discrepancies between our program and the physical part, it will modify that welding path to match the part.”

House said they have in-depth support for welding, with over 200 different variables for welding applications alone. Users can modify variables like torch tilt, torch twist, push/pull angle, and touch sensing with their program.

Also common in the latest OLP and simulation tools is drag-and-drop functionality. Everything is very visual and designed to be intuitive to make it easier to use.

“Rather than plugging in numbers to position components, you can simply drag from the catalog and snap it onto something like a robot pedestal,” House said. “You can drag which tool you want to use and it will automatically snap to the end of the robot. You can even hover over a part and it will highlight an entire toolpath around that part for something like trimming. Then you can click once and it develops that entire path.”

One OLP tool, multiple robot brands

A key advantage of third-party simulation and OLP software is its universality. Most can manage multiple robot brands. This is in sharp contrast to the OLP solutions offered by robot manufacturers. Robot OEM software is proprietary and specific only to one brand. OCTOPUZ has an online catalog of components included in their software. House says there are thousands of components in their library, including all the major robot brands and their various models.

“Many integrators we work with have multiple robot brands,” House said. “Rather than learning a number of different tools to program each one, they find it beneficial to have one tool to program all of them.”

Collaborative robots and OLP

Collaborative robots can often be “taught” an intended path via a lead-through teach feature. A user pushes the arm to the desired position and records the points. However, complex edge-following tasks often call for a more sophisticated programming solution than the standard platform that comes with some of these collaborative robots.

House said they have a number of customers using collaborative robots. Glue dispensing is a popular application for collaborative robots, which are designed to work in tight spaces near their human coworkers without safety cages.

“It all comes down to the application, not the robot,” House said. “For a pick-and-place application with only four or five points, you can drag the robot arm manually from point to point. But if you have a complex edge-following dispensing program you want to do with a robot, you can program it manually, but it’s going to be very time-consuming. That’s where software will help.”

Figure 7. NASA researchers use collaborative robots and OLP software to automate an otherwise tedious thermal inspection process for composite aircraft. Courtesy: RoboDK Inc./Robotic Industries Association (RIA)

Figure 7. NASA researchers use collaborative robots and OLP software to automate an otherwise tedious thermal inspection process for composite aircraft. Courtesy: RoboDK Inc./Robotic Industries Association (RIA)

Simulation and OLP software helped researchers at NASA Langley Research Center automate a novel aircraft inspection method using collaborative robots. The collaborative robot is equipped with infrared inspection cameras, which can detect material or structural defects in composite aircraft fuselages without damaging them by analyzing the flow of heat through the structure.

The inspection system is bulky and heavy, and must be moved across the entire exterior and interior surfaces of the fuselage. While the collaborative robots handle the heavy lifting, RoboDK software simulates and programs the inspection pattern to help ensure the robots don’t miss any areas.

But why use OLP when collaborative robots are supposed to be easy to program? Nubiola said that while the user interface is designed to be simple and is made for people who have never programmed a robot, for more sophisticated operations, collaborative robots may need to learn something beyond their initial programming, which is intended for more basic operations.

Consider a complex process like NASA’s inspection system, where the thermal sensors are analyzing hundreds of points. In this case, OLP software is a practical solution. Manual operation or even point-to-point robotic programming would be tedious. It would take three or four people to do the same thing one robot and one operator can achieve.

Using calibrated 3-D CAD models of the robot, fuselage, and inspection tool, NASA uses RoboDK software to not only generate the robot paths, but also test for the most efficient path. Automating the process with a robot also creates digital data of the inspection that can remain with the vehicle record. Subsequent test results on the exact same areas can reveal structural and material changes over time.

Figure 8. OLP software simulates robot path planning for a novel inspection system under development at NASA. The system uses collaborative robots equipped with infrared cameras to test for defects in composite aircraft structures. Courtesy: RoboDK Inc./Robotic Industries Association (RIA)

Figure 8. OLP software simulates robot path planning for a novel inspection system under development at NASA. The system uses collaborative robots equipped with infrared cameras to test for defects in composite aircraft structures. Courtesy: RoboDK Inc./Robotic Industries Association (RIA)

An inspection system using one collaborative robot on a wheeled base has been in testing at NASA for about a year. Nubiola said a new version of the system, which uses two collaborative robots working together on the same linear rail, has been in testing for a few months. This speeds inspection time and saves an operator from having to repeatedly wheel the robot from one section of the fuselage to another. The movements of the two collaborative robot are coordinated in the simulation and subsequent program. The setup brings this system one step closer to a production scenario.

Less time programming, more time producing

In a perfect world, a virtual solution should replicate the physical world. However, part and process variances, or deviations, can throw a monkey wrench into a company’s simulation and OLP setup. That’s where calibration is critical. Complex robotic processes and sophisticated software are no longer the exclusive domain of megacorporations. High-mix, low-volume job shops can join the OLP party. So can collaborative robots.

Tanya M. Anandan is contributing editor for the Robotic Industries Association (RIA) and Robotics Online. RIA is a not-for-profit trade association dedicated to improving the regional, national, and global competitiveness of the North American manufacturing and service sectors through robotics and related automation. This article originally appeared on the RIA website. The RIA is a part of the Association for Advancing Automation (A3), a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavra@cfemedia.com.


Keywords: robots, robot programming, collaborative robots

Robot offline programming (OLP) is believed to be too complicated and not cost-effective for companies.

Companies have been working to make their programs easy-to-use and flexible for many different brands and applications.

Collaborative robots can be programmed to learn more sophisticated and challenging applications that go beyond their initial design and purpose.

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Where can OLP help your company in the short- and long-term?

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