Robotised Machine Tending

With MOTOMAN RobotsBuilt to perform

Robotised Machine Tending

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Robotised machine tending increases productivity. Whether tending one or several machines, the robot workscontinuously and unmanned operation is possible.

Workshop example

YASKAWA Solutions for Robotised Machine Tending

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ProductivityA robot operated machine or group of machines will bemore productive than manual operation because therobot works continuously with constant cycle times andmakes unmanned operation possible.

With robotised operation a virtual simulation of the cellwork flow can be easily undertaken. This allows cycletimes to be accurately estimated or verified andproduction costs defined. Signals, opening/closing ofsafety devices, work piece deliveries, cleaning operationetc. are included in cycle time calculations to ensureaccuracy.

Robotised operation also means that heavy,monotonous and perhaps risky tasks are removed fromthe staff’s duties and they become robot operatorsinstead. This is often a positive change that increasesmotivation.

FlexibilityRobotised operation offers flexibility. It is possible tocombine robotised operation with manual operation.For example, it is possible for a cell to contain severalmachines, some of which are manually operated whilethe robot is operating the others. Safety zones andbuffer storage ensure safety and increased productivity.

Depending on the requirement it is also possible formachines in robotised cells to be operated manually ifthis is necessary for the production of prototypes orsmall batches.

ProfitabilityRobotised operation is ideally suited to the manufactureof recurring products in reasonable batches, but eventhe production of small batches can be profitableautomated by robot if the products resemble eachother and the similarities are used to make up a totalvolume that is large enough.

If the opportunity for unmanned operation is used, thecell will become profitable even faster. To increase theproductive time of the cell during unmanned operationthe cell can be provided with buffers, a place for infeedpallets, or conveyor systems for transporting goods inand out of the cell.

Robotised operation also increases profitability byincreasing quality. As a result of the robot’s exactmovements the number of products that need to bediscarded is diminished.

Automatic machine tending with an industrial robot is a flexible solution which makes it possible to make changes in the cellaccording to production requirements.

Robot + machine = increased productivity!

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Industrial robotsThe MOTOMAN robot family comprises a large rangeof six axes servo powered industrial robots. Robotssuitable for machine tending are available with amaximum payload, including gripper, from 3 to 500 kg.

In order to increase the robot’s reach it is possible tointegrate a seventh axis in the control system either as arotating robot turntable or a traverse track. Theturntable increases the maximum reach by up to 1100mm while the traverse track can transport the robottwenty meters or more.

Gantry robotYASKAWA’s product range also includes two and threeaxis gantry robots with a maximum payload of up to500 kg/robot arm. The gantry robot tends the machinefrom above which means that even during robotoperation the operator has access to the machine’sfront.

The gantry robot is equipped with one or several arms,which it moves along a beam. The arms can havenormal or rotation grippers, in which case the gantryrobot will also be able to perform pendular or rotatingmovements.

The linear gantry robot can move its arms up to 30-40meters and the horizontal gantry robot, which has onemore axis for movement, can use its arms over a wholesurface area.

A servo powered robot turntable, integrated in thecontrol system, is often used to increase the robot’sreach.

The horizontal gantry robot with one arm for machinetending which can work over a small surface.

A traverse track can be assembled to a suitable length fromany number of 3-meter modules.

Tending machineYASKAWA has experience of installations with millingMachines, athes, grinding machines and special machinesof all the leading brands*, for example: Brother, Danobat,Gildemeiser, Haas, Heller, Hüller Hille, Ixion,Kellenberger, Liebherr, Lidkö ping, Matsuura, Mauser,Mazak, Mollart, Monfort, MoriSeiki, Nagel, Nakamura,Okuma, Pittler, SAJO, Soarer, SMT, Stama, UVA.

*) The machine’s interface must be approved by YASKAWA.

Robot and machine

YASKAWA Solutions for Robotised Machine Tending

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A simple cell for mixed productionThis cell is designed for mixed production, where themachine can be tended either by robot or human operator.

The design takes into consideration the operator’s need forspace in front of the machine when operating or changingtools. The operator is also able to keep his raw materialclose to the machine. The robot has been mounted in sucha way that it does not take up unnecessary space whilebeing parked in its idle position.

The cell’s safety zones are designed so that material can betransported in and out of the cell without the need to opendoors and interrupt production.

Increasing the automationThe robot cell can be made more automatic by addingequipment for palletising, de-burring, measurement etc

Work shop exampleRobot cell for a single machine. Manually changeablerobot grippers, a platen conveyor with 20 plates. Therobot is mounted on a tilting robot stand which increasesthe operator’s access to the front of the machine.

1. MOTOMAN industrial robot (idle position)2. Robot controller3. Lathe4. Platen conveyor5. Pallet6. Photo cell (alerts operator)7. Light guard (breaks the safety circuit)8. Interlocked sliding door9. Safety fence

The platen conveyor is well suited for irregular objectswhich will be positioned exactly on the conveyor. If neededfixtures can be added to the plates. The conveyor design iscompact and reliable and constructed for a maximumpayload of up to 20 kg per plate.

With the robot on a tilting robot stand, the operator hasbetter access to the machine when the robot is idle.

Robot and operator sharing the same cell

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Large volumes in serial flowProduction of large volumes of similar products in a serialflow is well suited to automation with industrial robots.

It is also possible for such a cell to incorporate access tothe machines for the operator. More than one safety zonemakes it possible to operate one machine manually whilethe robot is busy in the other parts of the cell.

Using light guards instead of sliding doors makes thetransport of material with a forklift in and out of the cellmuch easier.

Palletising with layer sheetsLetting the robot palletise the products on a pallet withseparating layer sheets saves manual labour beforedelivery. The layer sheet can be specially designed for aparticular product or can be standard material such asmasonite.

Manual measurementThe robot delivers work pieces to a manual measuringstation in the safety fence. The measuring interval isprogrammed into the robot job beforehand.

Through the manual inspection hatch in the safety fence theoperator can pick up work pieces for measuring. A suitableinterval for measuring is simply programmed into the robotjob.

There will be one less manual task before delivery if therobot is able to palletise the products with separating layersheets. The robot changes to a vacuum gripper in order tohandle the sheets.

A large volume of similar products

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A robot cell with several machines for volume production of similar products. The robot picks up details from a conveyorbelt, tends a milling machine in two steps, de-burrs and finally palletises with layer sheets.

1. MOTOMAN industrial robot2. Robot controller3. Lathe4. Draw broach5. CNC machine6. Manual inspection station7. Deburring station8. Parts feeder9. Pallet and layer sheets10. Conveyor belt11. Photo cell (alerts operator)12. Light guard (breaks safety circuit)13. Safety fence

Workshop example

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More than one cell with one robotWith a gantry robot it is possible to simultaneouslyoperate two neighbouring cells. The gantry robot has oneor more arms that can be moved on a long beam.

Each cell contains its own tending machine, equipment formeasurement, labelling, in and outfeed conveyors etc. andbetween themselves they can manufacture differentproducts. On the other hand it is possible for them toshare other equipment, like a washing machine, markingstamp or similar machine.

Access during robot operationBoth cells can also be tended manually. It is possible forthe operator to be standing in front of the machine evenwhen the robot is in operation. This is due to the factthat the gantry robot’s arm is performing its tasks fromabove, through the machine’s roof.

Controlled by a cell computerWhen there are several production units working inunison, or if there is a need for supervision anddocumentation, a cell computer can be used.

The cell computer gathers the information it needs to runthe plant with regard to order intake, storage buffers,alarms and documentation. It provides a complete pictureof all production units and can transfer the correctmachine tending program to each machine. With a cellcomputer it is easy to run the whole plant from one singlelocation.

From the cell computer’s touch screen it is easy to select andstart the next robot program.

The gantry robot tends the machine from above with itsvertical arm.

Vertical Positioning RepeatableGantry robot Payload stroke speed accuracy Sound level

M12-Y 30 kg 1200 mm X=100 m/min ± 0.1 <75dB(A)Y=70 m/min

Z=70 m/min

M15 50 kg 1500 mm X=100 m/min ± 0.1 <75dB(A)

Z=70 m/min

M15 100 kg 1000 mm X=75 m/min ± 0.1 <75dB(A)

Z=50 m/min

M25 170 kg 1500 mm X=65 m/min ± 0.5 <75dB(A)

Z=35 m/min

M25 250 kg 1000 mm X=65 m/min ± 0.5 <75dB(A)Z=35 m/min

Horizontal gantry robot

Linear gantry robot

Technical data for YASKAWA gantry robots

One cell - two separate systems

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The linear gantry robot is serving two cells, each of them equipped with a lathe, an automatic measuring machine,infeed and outfeed conveyors. The gantry robot’s arms are working vertically and they are tending the machine fromabove, which gives the operator access to the machine front even during robot operation. A single computer controlsthe whole plant.

1. MOTOMAN gantry robot2. Cell computer3. Lathe4. Platen conveyor5. Measuring machine6. Washing machine

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Large volumes in parallel flowA robot cell for several machines can be constructed for aparallel work flow, i.e. different products are manufacturedin the cell at the same time.

The safety around the cell is designed so that one orseveral machines can be tended or adjusted manuallywhile the robot operates the other machines. Eachmachine has its own security zone protected by a laserscanner.

The transport of materials in and out of the cell isperformed so that robot operation is not interrupted.

Wide range of similar productsWhen the products resemble each other, it is possible touse the similarities to simplify the robot jobs withparameter programming.

In this case the grippers are designed to handle as many ofthe products as possible, or all of them, in order tominimize the need for a gripper change or tool adjustmentbetween different batches.

It also makes things easier if the work pieces can bepicked up by the robot from a datum magazine which hasbeen designed to fi t the whole product range.

Operator access increases with one safety zone in front ofeach machine. During manual operation it is then possiblefor the robot to operate the cell’s other machines.

Useful features in the control system

Parameter programming means that only some dimensions from the work piece and the finished productmust be fed into the control system which then adjusts the robot job to suit the actual product.

The Search function is useful if there are variations in the dimension of the work pieces or their position onthe pallet. Data from a sensor automatically adjusts the robot job.

The function Servo Float lower the power to the servo motors and makes the robot arm responsive toexternal forces, e.g. when placing a work piece against a tool.

Conveyor synchronisation means that the robot’s motions follows the speedand position of the conveyor. This function can be used pick up as well asplacing work pieces onto the conveyor without stopping it.

The integrated Collision control prevents robot, tools, fixtures etc. from beingdamaged during a possible collision. The momentary limits can be individuallyset depending on the application.

The control system can communicate with a PC using a PC-card (PCMCIA),serial RS-232C or Ethernet connection. For complex I/O installations there is afieldbus board available which supports the most common standards (Interbus-S, Device-Net, Profi bus etc).

Managing a complete product range

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A robot cell with several machines for volume production of similar products in a parallel work flow. One or severalmachines can be tended manually. The whole cell uses parameter programming where a few dimensions are fed to acell computer which then adjusts the robot jobs.

1. MOTOMAN industrial robot2. Robot controller3. Lathe4. Cell computer5. Vision camera6. Datum magazine7. Outfeed conveyor8. Laser scanner9. Safety fence

Workshop example

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Volume production in small batches“ Just-in-time” production often means many small batchesof similar products that together make up a larger volume.The work flow through the cell is always serial, but theoperations involved may differ from one product toanother.

In this case more than one gripper may be needed, not justfor the products but also for the palletising with layersheets. Here it is often profitable to use an automaticgripper changer where the robot changes its tools by itself.

A vision system may also be incorporated into the cell ifincoming parts are hard to position exactly. In this case therobot will be guided by a camera. The whole plant iscontrolled from a cell computer which also automaticallychanges programs in machines and robots.

Testing and identificationProducts can be automatically measured and marked in thecell in order to maintain quality and ensure identification.

Products with irregular shapes can be diffi cult to place sothat the robot has an exact position to collect them from.The solution can be a vision system for robot guiding duringpick-upBy mounting a temporary flange on the products it is possible

to have them all turned in the same lathe without changingtools. A smaller robot is assembling the flange with a screwdriving end effector.

Just-in-time production

YASKAWA Solutions for Robotised Machine Tending

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A robot cell for large volumes of similar products in small series The cell includes: vision system to guide the robotduring pickup, automatic marking and measuring equipment, automatic gripper exchanger. The cell is controlled bya cell computer.

1. MOTOMAN industrial robot2. MOTOMAN gantry robot3. Robot controller4. Cell computer5. Infeed conveyor with

vision camera (ceiling)6. Pallet magazine7. Automatic gripper changer8. CNC machine9. Screw driver (robot station)10. Lathe11. Measuring machine12. Marking stamp13. Layer sheets14. Safety fence

Workshop example

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Material transportThere are many ways of transporting material in or outof the robot cell. Some of the alternatives are: platenconveyor, pallet (datum magazine), fl at belt conveyor,gravity or powered roller conveyors, rotating tables, cartsetc.

The best solution for a particular cell depends on theproduct itself, the cell’s cycle times, batch size and thetype of production before and after the robot cell.

Gripper toolsThe robot’s grippers are constructed from standardcomponents which makes them easy to assemble andmodify at a reasonable cost. A gripper can also bedesigned to handle more than one type of product or formaking manual changes easier.

Changing grippers manually can be avoided with anautomatic gripper changer where the robot changes itsown tools when needed. The robot can also be equippedwith a permanently mounted gripper with manyfunctions, providing there is sufficient room for the robotto manoeuvre in the cell and that it has adequate payloadcapacity.

Turning stationIt is not unusual for the work piece to need to be turnedonce or twice to be machined in several steps. Theturning station can either be active or passive. An activestation is a gripper with rotating abilities and the passivestation is simply a place where the robot makes a re-grip.

Cleaning machine partsThe robot can be equipped with a nozzle and valves sothat it can regularly air blast work pieces, fi xtures andmachine parts.

Keeping the contact surfaces of the machine free fromdust and debris is important in order to be able tomaintain standards of manufacturing quality.

Transporting material on a roller conveyor for Euro pallets.

The robot can change its own tools with the automaticgripper exchanger.

Making sure that the machine parts are regularly freedfrom dust, debris and shavings ensures that products can bemanufactured with precision and quality.

Useful equipment

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Vision systemsSome products are difficult to palletise so that they can bepicked up by a robot. This can be solved with a systemwhich provides the robot with the visual information itneeds to locate the products.

The YASKAWA control system for robots is alreadyprepared for communication with a vision camera. Thecamera images can guide the robot in the same plane ordetermine the angle of incoming parts. The robot guidingis based on two-dimensional pictures. To achieve therequired contrast between objects and background extralighting can be installed or the material on which thepieces are presented changed.

Other forms of robot guiding are also available. Amechanical sensor connected to the control system isexcellent for height detection and can be used when therobot needs to search down in order to pick up the nextpiece in a stack.

DeburringThe robots programmable free movements enable it tofollow the work piece’s outline for example duringbrushing, polishing or de burring. It can either hold theworkpiece towards a fi xed/fl exible deburring tool or viceversa, i.e. handling the de-burring tool to a fi xed workpiece.

Measuring equipmentProducts can be measured either with automaticmeasuring equipment within the robot cell or manually,from a manual inspection station where the robot deliverswork pieces to the operator. The interval for measuringcan be programmed into the robot job.

Tracking and tracingFor production that requires the need to track and traceproducts there are many kinds of marking equipment thatcan be integrated in the robot cell. Some examples aremechanical marking stamps or ink jet printers which canprint on labels or the product itself.

Two-dimensional pictures from the vision camera canhelp the robot orient itself to unevenly positionedparts.

Products can easily be measured on a regular basis in theautomatic measuring machine within the robot cell.

Useful equipment

Technical data may be subject to change without previous notice.

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