A robot equipped with 2D vision sensor locates and picks a 'H' frame and transfers it to a dual-arm robot, which manipulates for arc welding, then on to second system for machining.FANUC Robotics America will demonstrate the assembly of a heavy-duty off-road vehicle 'H' frame using a variety of intelligent robots and the new R-J3iC Controller during IMTS 2006 at McCormick Place in Chicago, USA. At the show, a FANUC M-900iA/600 robot equipped with the iRVision 2D vision sensor locates and picks up the 'H' frame and transfers the part to a dual-arm M-710iC/70T Toploader robot. The new M-710iC/70T presents the frame to quad-configured ARC Mate 100iBe arc welding robots and serves as a positioner for a coordinated welding simulation sequence.
The dual-arm M-710iC/70T then hands off the frame to the M-900iA/600, which also serves as a positioner for two F-200iB parallel link robots that demonstrate a coordinated material removal simulation.
All FANUC robots use the new R-J3iC Controller.
The new R-J3iC Controller uses high-performance hardware and the latest advances in network, integrated iRvision, and motion control functions, providing a level of intelligence never offered before, including the ability to control 40 axes with one controller (four robots plus other equipment).
* iRVision - FANUC Robotics' new iRVision, is an easy to use, integrated robot vision option for the new FANUC R-J3iC Controller.
The iRVision System is the company's first built-in vision package that is available on all R-J3iC controllers, providing customers a single source for robot guidance or process feedback.
The FANUC iRVision system is a ready-to-use robotic vision package, requiring only a camera and cable - no additional processing hardware.
It has a 2D robot guidance tool to accomplish part location, error proofing, and other operations that normally require special sensors or custom fixtures.
* R-J3iC - multi-arm controller and coordinated motion - the new intelligent robot controller's motion enhancements shorten cycle times, reduce programming time, increase speed, and improve accuracy for multi-arm coordinated motion.
The R-J3iC offers customers the ability to control four robots in a coordinated fashion within the same work zone from one controller.
The R-J3iC also offers the ability to control multiple robots in a coordinated fashion with multiple processes in multiple controllers.
These systems with multiple robots in a compact work cell maximize reach capabilities, reduce tooling costs, increase productivity, and enhance manufacturing process flexibility.
Controlling multiple arms with the R-J3iC can reduce system safety interlock and cell integration hardware costs.
The modular and compact packaging of the R-J3iC multi-arm controller also helps reduce hardware costs and floor space requirements.
Flexible programming of the R-J3iC multi-arm controller enables independent motion, simultaneous motion, and coordinated motion to meet the needs of various material handling and material joining applications.
Interference avoidance is essential in a multi-arm working environment, especially when multiple robots are operating independently.
The R-J3iC offers the capability to avoid collisions in multiple robot applications.
To maximize production throughput, multiple robots may be programmed to perform independent tasks.
These tasks can be executed all at once or multiple robots may be synchronized at specific programmed locations.
When specific robots are required to start and complete motion at the same time, simultaneous motion with a single program may be used.
'Multiple robots operating in parallel to process multiple parts or different sections of the same part maximizes robot utilization and increases production throughput,' said Jason Tsai, general manager, motion and applications product development, FANUC Robotics.
Coordinated motion can be used when multiple handling robots are required to carry the same part.
This significantly increases the payload carrying capacity, enabling applications never before possible with electric robots.
Multiple arms could effectively function as a flexible load/unload device.
'In a welding cell, for example, multi-arm control allows customers to achieve maximum utilization of their robots.
Using one or two robots for material handling while other robots perform welding maximizes flexibility,' said Tsai.
'By simply changing the end-of-arm-tooling (EOAT) on the material handling robots, a wide variety of parts can be welded within a single work cell.' * New M-710iC/70T Toploader Intelligent Robot - he M-710iC/70T Toploader is FANUC Robotics' latest articulated gantry robot.
The new robot is an ideal solution for medium to large machine tending and material handling operations.
With a wide selection of rail lengths, a payload range of 10 to 200kg, and reach of 1.5 to 2.2m, the Toploader series meets virtually any application need.
FANUC Robotics offers the most versatile line of robots in this class.
'A combination of benefits makes the Toploader series the perfect solution for machine tool load/unload and injection molding machine extraction,' said Ian Orr, product manager for FANUC Robotics.
'Compared to traditional linear gantry robots, our Toploaders reduce floor space and ceiling height requirements.
They also provide six-axis dexterity to perform value-added post-processing operations such as degating, deflashing, labeling, quality assurance, packaging and palletizing.' The M-710iC/70T robot has a 70kg payload and 1900mm reach and can be ordered in either an underslung or sideslung configuration.
The underslung configuration suspends the robot arm underneath the rail structure and offers a symmetrical work envelope on both sides of the rail while the sideslung configuration suspends the robot arm off the side of the rail structure and allows for maximum vertical reach and maximum stroke.
The sideslung configuration is the only viable configuration when using a Toploader robot to tend a press such as an injection molding or die-cast machine.
Customers can choose the configuration based on the needs of a specific application.
Other key features and benefits of the Toploader series include the following.
All FANUC Toploaders are standard products and come complete with full product documentation, standard software and 24-hour Hotline support.
The gantry structures are designed, tested and supported by FANUC Robotics as part of the standard product.
Toploaders use the same industry-leading motion software as FANUC pedestal robots - new features and updates are automatically supported with minimal or no tuning required.
The overhead configuration of all Toploader robots removes the robot from the factory floor, allowing users to optimize machine placement, product flow and waste removal of chips and other debris in machining operations.
A modular rail design allows users to select standard rail travels in increments from 2.4 meters to 45m.
A modular column design gives users similar flexibility to specify rail height and column location along the rail.
A unique adjustable column design lets users fine tune the rail height at installation or to account for irregularities in the plant floor.
Dual-arm (two robots sharing the same rail) configuration available to accommodate heavy parts.
Dynamic Space Check allows real-time interference avoidance at very high motion speeds.
In addition, synchronous motion stop control allows simultaneous motion stop for all Toploaders on the same rail.
The Toploader robots are targeted at machine tool load/unload, injection molding machine load/unload and process applications such as die spray and dispensing.
Since their introduction, they have also been used for numerous arc welding, painting, palletizing/de-palletizing and dispensing applications.
* ARC Mate 100iBe Solution Arm - the ARC Mate 100iBe Solution Arm is a 6-axis intelligent robot, which provides a cost-effective solution for welding parts of all sizes and configurations.
Its compact size helps maximize reach in confined areas, allowing manufacturers to install multiple robots in close proximity, and save valuable floor space.
Its size also allows the robot to access parts in tight locations without compromising torch angles or weld quality.
The unique design provides increased arc density because the torch cable does not interfere with other robots or tooling as in a traditional torch dress-out.
Improved arc density helps reduce capital costs.
FANUC Robotics' ROBOGUIDE WeldPRO simulation package easily models the Solution Arm dress-out, and downloads programs to the robot, which run without touch-up.
The company's exclusive torch cable design is inherently robust, capable of 500 amp capacity, and is simply air cooled.
Using the patent-pending RobotCAL calibration software, which improves path performance, FANUC robots have absolute positional information of each other, improving arm-to-arm collision avoidance and coordinated motion' 'The RobotCAL package eliminates human error while being a cost-effective solution when compared to third-party lasers, positional detectors or external sensors,' said Mike Sharpe, FANUC Robotics' manager of materials joining'.
'This is possible since the ARC Mate has a simple touch-plate and a built-in touch sensing circuit.' Sharpe said: 'Another product that differentiates FANUC Robotics from the competition is ArcLink XT, a flexible and powerful welding network that allows us to control up to four welding power supplies with one R-J3iC Controller.' ArcLink XT is the 'next generation' in arc welding network communications offering improved performance over existing welding communication methods.
The connection to the welder is over the standard R-J3iC Ethernet connection.
'The control of four robot arms and four independent welding power supplies with one CPU and teach pendant has been unheard of in the industry until now.
FANUC Robotics, together with Lincoln Electric offers this dynamic and cost-effective intelligent welding package,' said Sharpe.
According to Sharpe, the ArcLink XT software is fully integrated with the Lincoln Electric Integra power supply and the robot control cabinet, offering full waveform control and 350-ampere capacity in a symbiotic package.
'Place, power and weld; it is that simple for clients to start production with this integrated welding package.' He added: 'This cost-effective robot is powerful, reliable and offers excellent value, while the R-J3iC offers extensive expandability.
All users from Large Tier suppliers to smaller shops will find the ARC Mate 100iBe Solution Arm an attractive and low cost alternative to labor intensive arc welding.' * Benefits of the new ARC Mate 100iBe include the following.
'Best in class' reach versus stroke ratio.
Compact design simplifies installation and transportation of system.
Provides high throughput.
Allows operation in tight work spaces.
Lower operation and installation costs.
* M-900iA/600 Intelligent Robot - the M-900iA/600 is an ultra heavy-duty material handling robot with a 2.83m horizontal reach and a 700kg payload capacity.
The M-900iA/600 is capable of handling very large and heavy parts such as sand core packages, engines, powertrain components, large vehicle frames, various castings, molded parts, glass, and building materials in a variety of applications including machine tending, part transfer and other handling processes.
'The impressive 600kg payload of the M-900iA/600 creates opportunities in application areas where robots have never been applied,' said Orr.
'The M-900iA/600 will help reduce manual labor costs and diminish the need for expensive fixed and custom automation equipment like gantries, hydraulics, chains and saddle devices.' Featuring a modular construction, the electric, servo-driven M-900iA/600 provides precise, high-speed operation and easy installation.
The M-900iA/600 meets the needs of an increasing number of customers that require maximum reach and lifting power.
The robot offers substantial improvements in wrist capacity (250% increase in wrist moment and a 430% increase in wrist inertia) compared to its predecessor.
Like the M-900iA/350 and M-900iA/260 Long Arm, the 700kg robot offers 'best in class' wrist capacity and axis speed, providing manufacturers maximum flexibility for tool design and part handling.
The M-900iA/600 also offers an optional IP66/67 harsh environment protection package.
In addition, the M-900iA/600 robot's small footprint helps reduce floor space requirements.
* F-200iB Parallel Link Robot - designed for use in a variety of manufacturing and automotive assembly processes, the powerful and compact F-200iB is engineered for applications requiring extreme rigidity and exceptional repeatability.
'The F-200iB is a lean robot that provides maximum versatility while requiring minimal floor space,' said Virgil Wilson, material removal product manager, FANUC Robotics.
'Achieving optimal production while using the least amount of space is an important concept of lean manufacturing.' The superior rigidity and payload of the F-200iB makes it well suited for a wide range of applications including flexible fixturing, nut running, spot welding, nut/stud welding, part loading and dispensing, It is also ideal to meet the rigors of material removal applications including heavy-duty deflashing, drilling and hole cutting.
The F-200iB is capable of significantly higher feed rates versus a serial link robot, with up to 200mm/s for deflashing aluminum castings and up to 35mm/s for hole cutting of 3mm thick cold rolled sheet steel.
The F-200iB also has increased accuracy due to less robot deflection versus a serial link robot, provides increased tool life due to less vibration and tool chatter, and can include semi- or fully-automatic tool change.
* About FANUC Robotics America - FANUC Robotics America designs, engineers and manufactures industrial robots and robotic systems for a wide range of applications including arc and spot welding, material handling (machine tending, picking, packing, palletizing), material removal, assembly, paint finishing and dispensing.
The company also provides application-specific software, controls, vision products, and complete support services.
After 24 years of success, FANUC Robotics maintains its position as the leading robotics company in the Americas.
A subsidiary of FANUC in Japan, the company has facilities in Chicago; Los Angeles; Charlotte, North Carolina; Cincinnati and Toledo, Ohio; Toronto; Montreal; Aguascalientes, Mexico; and Sao Paulo, Brazil.
Over 155,000 FANUC robots are installed worldwide.
* FANUC Robotics America at IMTS, Chicago, USA, September 6-13, Booth A-8418.