Collision-Free Path Redesign

Engineering Context

A fixture was added to an existing workcell, creating a collision risk along the original direct path. Engineers need a new path that preserves production speed and maintains a documented safety margin.

What You Will Practice

• Identify collision zones in a digital model
• Create safe intermediate waypoints
• Compare path length and cycle time
• Verify clearance in simulation and physical operation

What You Need

• Digital twin
• Physical workcell if approved
• Virtual obstacle/fixture
• Python program
• Measurement tool
• Engineering notebook

Instructions

1. Run the original path in simulation and capture the collision location.
2. Define a required clearance margin around the obstacle.
3. Create three alternative waypoint paths.
4. Measure or estimate path length for each.
5. Simulate each path and record cycle time and minimum clearance.
6. Select the shortest path that meets the clearance requirement.
7. Verify the selected path at reduced speed on the physical cell.
8. Document final coordinates and the reason each waypoint exists.

Engineering Requirements

• Zero collisions in ten simulated cycles
• Maintain the required clearance margin
• Add no more than 20% to original cycle time
• Verify one reduced-speed physical cycle

Constraints & Safety

• Do not remove the obstacle
• Do not exceed the approved work envelope
• All waypoint coordinates must be documented
• Physical verification requires teacher approval

What You Submit

• Collision screenshot
• Three path concepts
• Clearance/cycle-time comparison
• Final code
• Physical verification notes
• Reflection

Reflection Questions

1. Why was the shortest geometric path not necessarily the safest?
2. Which waypoint added the most time?
3. How could tool orientation create a collision?
4. What sensor could monitor unexpected obstacles?