Updated May 2018 || Robots are increasingly viable for a range of automation applications. In fact, proliferation of robotic platforms that come in proven industrial formats, Cartesian setups, delta subtypes, and six-axis selective-compliance-articulated robot arms (SCARAs) has spurred more use than ever of robots for palleting, machine tending, welding, machining, packaging, assembly, and more. No matter the application, the robot morphology must match the task at hand.
Sysmac delta robots operate on a Sysmac-NJ controller, which is Omron’s all-in-one platform integrating robotic, motion and sequential logic control in one multitasking controller. Using the EtherCAT motion network, the NJ controller delivers top speed, accuracy and predictability. Other Sysmac features include control of up to eight robots by one NJ controller; coordination of four axes; cycles to 200 per minute; and 450 to 1,300-mm reach.
This is a Cartesian robot built of components (linear slides and actuators) from PHD, Inc. Particularly common in the packaging industry, such setups are increasingly modular.
ATI Industrial Automation’s Rail Tool Changers allow for quick and reliable exchange of press transfer tooling. ATI designed custom Tool Changers for Güdel transfer lines to withstand the high speed, high-inertia-loading environment of this process. This coupler upgrade mitigates problems that make other exchangeable rails get stuck between die changes. With numerous production runs and die changes every day by the end user, this is a significant productivity booster.
Applications that require robots to operate around personnel are leveraging the increase of integrated safety in robots of all morphologies … including everything from Universal-type cobots to the larger industrial robots traditionally associated with automotive applications. Here, integrated safety monitors robot position, speed, and torque … as well of the robots’ external barriers where applicable. Applications driving much of this move are consumer-electronics and warehouse-management industries, as their processes demand more flexible safety than other industries that use robots.
With payloads from 20 to 600 kg, Yaskawa Motoman’s high-performance HP robots are versatile manipulators that excel in myriad applications, including packaging and palletizing. HP-series robots also work in assembly and dispensing. Six-axis flexibility lets them execute complex handling motions and more in multi-function work cells. Heavier-payload models often go in jigless applications to position parts by up to seven additional robots (all controlled by one controller). HP robots mount to floors, ceilings, and shelves, and there are extended-reach versions. An FS100 open software architecture robot controller and a PLC-integrated MLX200 platform can control the HP20 (20 kg) model. Shown here is a case-packing setup using an HP20 robot and a gantry under servo control, both programmed with one piece of software. The setup also showcases Yaskawa’s Singular Control to let packing machinery to seamlessly use robot and motion control without special robot programming.
In contrast, packaging, wireless technology, and pharmaceutical applications have spurred robot manufacturers to make smaller and faster robots. Helpful here is that advances in controls and software have made integrating robotics easier … even for advanced functions such as verifying product packaging, for example.
Industries that lead the use of robotics are food and beverage and packaging. Though many manufacturers in these industries still use manual operations, there’s a steady move to automate processes so as to leverage its flexibility and high productivity.
Robot improves aircraft assembly
KUKA Systems Aerospace is supplying Gulfstream Aerospace with advanced mobile-robot platforms and assembly fixtures (wing boxes and other tooling) to help assemble wings and other parts for the company’s newest and fastest corporate jets.
Gulfstream has tooling from KUKA’s aerospace group for G500 and G600 planes scheduled for first deliveries in 2018 and 2019. Deliveries of KUKA G500 wing-assembly fixtures are done, and work continues on the G600 wing fixture box and other tooling.
“We see huge potential in the growing aerospace industry for intelligent automation,” said Dr. Till Reuter, CEO KUKA AG. “Gulfstream is an important reference customer for KUKA along with other giants of the aerospace sector.”
The wing assembly fixture is vertical structure … larger than the wing itself. Inside that structure go the ribs and spars of the wing (between the top and bottom skins for structural integrity). KUKA also built vertical hoists to lift the wing, flip it from vertical to horizontal, and transfer it to the next assembly station. Other KUKA tooling includes fixtures for building sections of the aircraft—ailerons, engine mount bulkheads, flaps, and leading and trailing edge panels.
Aircraft tooling is built using large components fabricated and machined to tight tolerances to locate and hold airframe components for assembly. It’s always custom to engineering specifications for each aircraft type. Fabrication involves multiple processes, depending on the tool type and function. Most have machined locators on a fabricated structure. The main structure is usually steel tubing, while part-touching details or critical locators are aluminum. Some tools are solid aluminum so the coefficient of thermal expansion matches that of the aluminum aircraft parts they are assembling.
The two mobile-robot platforms are KUKA innovations, and the first built by any U.S. manufacturer. The aim is precision drilling and fastening, with excellent repeatability, to increase the productivity and quality of the assembly process. Each mobile-robot platform has a KUKA robot and multi-function end effector. For Gulfstream, the mobile robot platforms drill primarily on the wing and horizontal stabilizer structures, including sections of titanium that are hard to drill manually.
The KUKA wing assembly fixture for Gulfstream is a long, vertical structure – larger than the wing itself – in which the wing is assembled.
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