news Focus Jungheinrich AG: Twin robot welding cell for drive frames

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1 news Issue 02_ 2007 Focus Jungheinrich AG: Twin robot welding cell for drive frames Report Austrian company Doka Schalungstechnik GmbH: Welding and handling of small components Report Insentec B.V.: Fully automatic production process for quality milk New MOTOMAN-EA1800N: Ideal for welding and handling

2 Foreword Contents Dear Customers, Dear Colleagues, Now it is time once again to present you with this new issue of our magazine MOTOMANNews. It was exactly five years ago that Johann Bauer and I started our new jobs at what was then the newly opened sales branch in Austria. It feels as though it were only yesterday. At that time, we'd set our sights high and planned to develop and sell as many customer-oriented automation solutions from the best robot manufacturer in the world as possible to customers in Austria. When I look back on that now, I think we did a successful job together of bringing the MOTOMAN robot brand to Austria, where it was little known up to that point. In the meantime, a lot of customers from a wide variety of industries invested their trust in us. And thanks to in-house support, we re still receiving even more. Of course, the numerous technical innovations from MOTOMAN/YASKAWA have made a significant contribution. Starting with the new robot control generation NX. Or the stars from our family of welding robots: types SSA2000 and EA1900N, the very first welding robots with fully internal welding hose pack, which revolutionised the market for welding robots. And then there are the numerous innovations in the field of handling robots, or the global launch of the single and dual arm types IA20 and DA20, with their 7 and 13 axes respectively. These examples reflect tremendous growth in the development of robot technology from our dynamic, progressive parent company in Japan. At this point, we ought to remember also to mention the technical developments and customer-oriented innovations from our centre in Allershausen. The most important thing for successful customer care is an exemplary team spirit; and a good working relationship. And both we and our Austrian customers would like to offer you our warmest thanks for all your efforts. Enjoy the magazine! Imprint MOTOMANNews Issue 2/2007 Editor: Marion Reisert, MartinaVogl Best regards, Josef Hautzinger Sales Manager Best regards, Ing. Johann Bauer Sales Engineer Technical consultancy and sales, Austria Design/Layout: Matthias Grießel and Angela Freiberger, Munich Production and print: Druckerei Vogl, Munich Authors: Alexander Steiger, Dietmar Stein, Heiko Röhrig, Josef Niedermeier, Josef Simon, Marion Reisert, Markus Klein, Martin Stenger, Martina Vogl, Johann Bauer, Josef Hautzinger, Stefan Hagspiel, Peter Stiefenhöfer, Ralf Deparade, Stephan von Schneyder, Tilo Dobmeier,Werner Willers Contents Foreword/Imprint News / A look at trade fairs The Joining Specialists in 2007: Indian summer in Basel 3 A look at trade fairs in Focus Jungheinrich AG: All-round solution A twin robot cell welds drive frames 4/5 Report Austrian company Doka Schalungstechnik GmbH: Welding and handling of small components 6/7 Insentec B.V.: A standard industrial robot optimises the fully automatic process for producing quality milk 8/9 New Very precise, robust, extremely fast and with its load capacity of 15 kg ideal for welding and handling tasks: the MOTOMAN-EA1800N 10 Shelf-type robots for use with low, medium, high and extreme payloads 11 Synchroweld the perfect interaction of robot and welding system 12/13 Slimarm robots ensure optimum performance! 15 Event Synchroweld Presentation in the Landstuhl Stadthalle : A roaring success 13 System partners LacTec GmbH: Robot concept sets new standards Automatic programming for efficient painting of small batch sizes 14/15 BBK Etikettier- und Sondermaschinenbau GmbH: Fast labelling of high stacks 16/17 WMS-engineering GmbH: Cooperating robots guarantee high quality for precision deburring 18/19 Trade fairs Successful appearance at Welding Week Use the appropriate robot for all installation and handling technology tasks, and European premiere for the smallest 6-axis robot at MOTEK austrotec.07 Innovation trade fair for the production process 21 International rendezvous for the automotive industry at the Zulieferer Innovativ annual congress 21 Stemmer Imaging GmbH: Opening the exhibition at the AUDI Forum in Ingolstadt with an HP3L 21 From one casting! 22 Sheet metal meets Business at Blechexpo & Schweisstec

3 News Fair outlook The Joining Specialists 2007 In Basel, Klaus Paulus pointed out the options and opportunities resulting from the use of new robot kinematics. In September, the DVS (Deutscher Verband für Schweißen und verwandte Verfahren e.v.) held its Great Welding Conference (Große Schweißtechnische Tagung, GST) and annual meeting for its members.this all took place in Basel between 16 and 18 September A number of events were all brought together under the new name The Joining Specialists; entitled Robots, Joining Plastics, Industry Forum Interaction and Research Forum. In the foyer of the Congress Centre, MOTOMAN used an exhibit to light-heartedly demonstrate the enormous freedom of movement and flexibility of the MOTOMAN-DA20 dual arm robot. It handled and welded a miniature robot out of metal parts and quickly became a real point of interest among visitors! Within the scope of the GST, Klaus Paulus (Sales Director at MOTOMAN robotec GmbH) discussed the options and opportunities resulting from the use of new robot kinematics. In his presentations, he provided information on the individual steps in the development of the novel 7, 13 and 15-axis single and dual arm robots. The new kinematics are applied in places where the old, conventional kinematics could never have been used; in fields such as assembly and handling, machine loading and unloading, and also to meet welding requirements. He mentioned the benefits for users: quality improvements, reductions in cycle times, savings, simpler tools and the implementation of combinations of movements. Work can be carried out in the very narrowest of spaces with the 7, 13 or 15 controlled axes, guaranteeing extreme movements (without interference). The innovative multi arm robot Intelligent automation solutions were demonstrated by means of practical examples; system concept permits a high concentration of spot welding robots such as the multi arm robot system concept, which combines conventional 6-axis around the bodywork (a total of 20 manipulators). industrial robots with 7-axis IA kinematics. In action: The DA20 dual arm robot handling and TIG-welding a miniature version of its robot colleague IA20. Fair outlook: Automatica 2008 Motek rd international trade fair Trade fair for robotics and automation for automation June September 2008 Place: Neue Messe Munich, Place: Stuttgart, Germany Germany Hall B2 / Stand 338 Hall 7 / Stand 7510 Fakuma 2008 The international trade fair for plastics processing October 2008 Place: Exhibition center Friedrichshafen, Germany Hall A7 / Stand

4 Focus All-round solution a twin robot cell welds drive frames at Jungheinrich AG Jungheinrich AG is one of the four biggest suppliers in the world of industrial trucks, storage and materials flow technology. Jungheinrich is a European leader in the field of storage technology. Since 1953, the company headquartered in Hamburg has been offering forklift-based products and services. With more than 600 vehicle variants, from hand pallet trucks to forklifts and order pickers, the company offers an extensive range of products suitable for all purposes. A 2-station positioner with five external axes is positioned in the extremely compact welding cell. Drive frames for type EJE pallet trucks and type ERE order pickers are manufactured at the Jungheinrich plant in Norderstedt (north of Hamburg). In late 2006, a robotic MAG welding system was installed by Helmut F. L. Grützmacher GmbH and commissioned in a very short time. Grützmacher Schweißtechnik is a locally based specialist company in Hamburg and supplies systems for welding mechanisation and automation. Twin robot solution Fully automatic production has been running at a cracking pace at the Norderstedt plant since the start of this year. Two MOTOMAN-EA1900N welding robots are integrated in a safety enclosure, with a programmable scanner in the inlay area. Drive frames for type EJE pallet trucks (with dimensions of 800 x 800 x 400 mm) and type ERE order pickers (800 x 800 x 800 mm) are manufactured at the plant. These are MAG-welded and processed using S235 and S355 (St 37/ St 52). The weld seam used for the EJE series is about 4 metres long, and the welding process takes about 8.5 minutes per workpiece. In the case of the ERE series, the weld seam is about 8.5 metres long and each component takes about 17 minutes to weld. A two-shift system is operated, five days a week. Each year, around 20,000 pallet trucks are produced, and about 5,700 order pickers. Workers manually place the components in a 2-station positioning unit (type R2L-500 ). The enclosure was designed as a compact cell with fold-down side walls, closed at the top and with an integrated extraction flue. The controls link the industrial robots to the system peripherals by means of a SPS based on the Siemens S7. The full welding equipment was provided by Grützmacher Schweißtechnik. This welding equipment includes the power sources AMT Hybrid 6000 M with a robot interface, DINSE REVO Torch System and DINSE DV case (including ZSP). Both welding jigs come from Jungheinrich AG. 4 Twin system: Convenient establishment of virtual safety zones allows the two MOTOMAN-EA1900N units to work synchronously in a very small space.

5 Focus 2 x AMT power source (provision of material by customer) Service door with inspection window Spool 2 (provision of material by customer) Extraction Control desk on stands NX100M + NX100S EA1900N Positioner R2L Adaptive control Nozzle cleaner EA1900N 1700 Interference area Ø Feed belt Customer side Spool 1 (provision of material by customer) Extraction with filter system (provision of material by customer) 5800 Base frame 3305 Drive frames for pallet trucks and order pickers are MAG-welded. COMARC NX seam monitoring system Another part of this system is the COMARC NX seam monitoring system. The COMARC3 current sensor automatically equalises the deviations between the programmed line and the component. This deviation is measured via the welding current during the movement of the welding torch, and this value is used to monitor the seam. R2L station positioning unit The positioning unit is based on a 2-station rotary indexing table with five external axes. The payload is a 500 kg per station, the fixture diameter is 1,600 mm and the load height is 875 mm. The drive for indexing the stations is implemented as an external axis, powered by an AC servo motor with transmission via a pinion/crown gear pairing. This permits very precise movement and braking, with extremely short table cycle times. As the axis works in synchronisation with the motion of the robot, there is no idle time due to limit switch queries. Two rotary tilting units, each with two external axes, are fitted on the main drive. Each of the twin drives is connected as external robot axes and can be moved steplessly within the working range. Use of these external robot axes guarantees the shortest positioning times, simple programming via the manual programming unit (known as a Teach pendant) and hence offers the option of incorporating positioning axes in the entire movement sequence. An eye protection screen in the middle of the table serves as a glare shield. Advantages of the automation solution The decision was made to invest in the MOTOMAN system because the innovative technology of the twin robot solution was immediately apparent. There are also other benefits, such as short welding times thanks to two arcs, less weld delay, the compact cell structure, short assembly and commissioning times, high delivery reliability and enormous system flexibility thanks to the compact structure of the welding cell. Jungheinrich AG is very happy with the twin solution implemented. The high level of uptime, our positive experiences with service and the proven reliability of the MOTOMAN-UP6 model which has been used in the manufacture of lift truck forks for five years, all contribute to this. Robotic automation has reduced non-productive time, shortened throughput times and brought about economic savings, explains Dietmar Stein, Managing Director of Helmut F. L. Grützmacher GmbH. 5

6 Report Tradition, scills, innovation the first three words in the Umdasch company brochure. This group, which has more than 100 branches worldwide, employs some 6,000 staff in the Doka-Schalungstechnik and Umdasch Shopfitting Group business areas.with more than 130 years of experience in shuttering technology, Doka based in Amstetten in Austria is one of the world s leading suppliers of innovative, complete shuttering solutions and services. Skills and innovation were also required in order to create a robot cell for processing small components for shutters which would save space and ensure great flexibility. The specifications included a compact cabinet a very high degree of automation and the shortest possible cycle time. Furthermore, various tasks and fully automatic quality control had to be carried out in addition to the core task; the welding of two individual spare parts. All in all, this provided MOTOMAN robotec GmbH with the ideal challenge to come up with a solution that could do all this. These were the results The robot cell was designed as what is known as a compact cell. It is designed around a transportable base with integrated protective guarding, thereby allowing the entire system to be transported very easily. It accommodates all of the equipment including three robots. which are are controlled as cooperating robots via a control system ( Triple Synchromotion function). This is the only way of allowing the three robots to work safely at the prescribed speed in such a tight space. First, the two individual spare parts are held for presentation to the robot in bespoke buffer storage magazines that contain around 100 parts. Before the double gripper of the handling robot removes the blanks, the component is preheated by means of a hot air fan. The second component receives an automatic imprint, a facility which is integrated in the magazine. The first robot, a MOTOMAN-HP20, picks up the blanks individually and then places them alternately in one of the two weld positioning tables. Then the welding work begins for the second robot, a MOTOMAN-HP6, which is equipped with Fronius welding equipment. The TPS 5000 is supplied with the optional RCU5000i remote control unit to ensure optimum parameter setting. This also allows the welding parameters to be monitored automatically, and an error message to be sent immediately to the robots in the event of irregularities. The component in question can then be placed in the NIO container so that subsequent manual inspection can be carried out. The components are manufactured alternately on two weld positioning tables. This means that the handling robots do not spend any time waiting and so the output can be increased accordingly. The welding robot is subject to very high up-time, so the welding equipment comes with a forced cooling device. A special extraction hood is fitted to the welding robot which works very efficiently by travelling with the robot. 6 The Triple Synchromotion function coordinates the three industrial robots fully synchronously via a shared controller. Here, the MOTOMAN-HP20 is fitted with a double gripper, the MOTOMAN-HP6 is fitted with a MAG torch and the MOTOMAN-HP20 is fitted with a finished component gripper. Work is carried out in the tightest possible space in this compact cell.

7 Report 2800 base frame This ensures concentrated extraction of the weld vapour, which means that the loading and unloading zones of the positioning tables are freely accessible at the same time. A torch cleaning device is fitted within range of the welding robot for automatic cleaning of the welding torch, and it also comes with a torch service station with an automatic Q-Set torch measurement system. This means that a repeat measurement can be carried out of the welding torch position if required. In the event of an offset of the previously set zero point (TCP), the robot automatically compensates for this in the program. If too great an irregularity (in other words a collision) occurs, the robot stops immediately so that the torch can be replaced manually. After welding, the third robot again a MOTOMAN-HP20 comes into play. This has a varied movement sequence to implement. First it travels with the component to the camera station, where a further quality assurance process takes place. The weld seam is measured visually to check the seam position and height. If the component fails to comply with the preprogrammed tolerance, it is returned to the NIO container. With the welding parameter monitoring described above, uniform quality can be assured with this additional inspection. If the component conforms to the quality requirements, the HP20 continues on to the marker station. Here, the component is provided with a coloured ring which indicates to the fitter the component tolerances to ensure safe installation. Once the individual manufacturing stages are complete, the robot places the components in one of two boxes for finished components base frame Power source TPS5000 Waste extraction 2 x positioners with fixture Nozzle cleaner BRG2000 TCP/threaded bar measurement Colour preparation Colour extraction NIO parts container QS parts container 800 Controller: NX100M NX100S NX100S HP6 with MAG torch and extraction Exhaust air flow 630 HP20 with finished part gripper Spool HP20 with double gripper Camera inspection/ measurement Adaptation controls Finished parts Unit 1 Finished parts Unit 2 The operator has the option of requesting a sample part for quality control purposes. Separate trays are provided so that staff can take the components out of the cell safely. To facilitate operation and improve clarity for the operator, the robot system comes with a parent system control unit (SPS) and a control panel with a plain text display. All in all, this robot cell meets all of the customer s original requests. It was installed in the smallest space possible, operates continuously at very high speed and produces components of top quality, with full self monitoring capability Unfinished parts Unfinished parts Conveyor belt - Feed - Control panel (can be rotated) The workpieces are produced alternately in two positioners, so the HP20 handling robots do not spend any time waiting. The third robot, a MOTOMAN-HP20, grips the component and brings it to the camera station, then on to the marking station, and finally the component is placed in one of two boxes for finished components. 7

8 Report Standard industrial robot optimises fully automatic production of quality milk Cows have been milked for several millennia, and the scheduling of milking has always been determined by Man. But for the past two years, cows themselves have been able to decide when and how often to visit the Insentec milking stand over the course of the day to be milked by a MOTOMAN robot. Insentec B.V., a subsidiary of Danish systems supplier S.A. Christensen A/S, developed an innovative milking system with two parallel milking stands, in collaboration with the specialists for cowshed automation. At the heart of these milking stands is the tried and tested MOTOMAN-HP20 industrial robot. This six-axis robot model has already proved its mettle as a reliable partner in many other areas of industry. The MOTOMAN-HP20 allows milking to be carried out without stress. 8 Milking using robots (special robots) is nothing new standard industrial robots can be used for this. This idea was the brainchild of Henk Hofmann from the Netherlands, who won the Golden Robot Award 2004 for his efforts. After somewhat long drawn-out efforts, he switched robot suppliers in 2006 and since then his customers have been delighted. The configuration of a standard system, as sold by Insentec under its own name or under the name of Holding SAC, has since proven very successful worldwide several hundred times over. Parallel system with two milking units One cell consists of two adjacent milking stands which are each protected by means of an automatically operated entry and exit rail. The cow reports its name by means of a data storage medium attached to a neck strap and enters the milking stand. The cow's favourite fodder is also stored, and this fodder is then dispensed in a special feed dispenser at the front of the milking stand. Then the MOTOMAN robot starts to do its job and scans the udder with a laser and vision system fitted to the robot head. Then it draws off the foremilk via an extractor unit also fitted to the robot head and cleans the teats. Now it takes the milking machine extractors by means of a special gripper system and places these extractors on the teats. While the milking machine does its job, the robot has time to operate the second, parallel milking stand. The close partnership between Insentec and MOTOMAN robotec led to a robot system customised in terms of hardware and software. A MOTOMAN-HP20 with enhanced protection class (IP67), special cables and special interface software for a laser and camera is used. This robot was specially adapted to survive the aggressive ambient conditions. Linear servo float But if the cow is not happy about its milking and objests to it, the software function with linear servo float (a coordinated soft switching of certain robot axes, so allowing the robot to adjust itself in a linear direction) yields to the pressure and automatically starts attempting to milk the cow again. However, as a rule this is not required as the voluntary milking system and stress-free milking process using the MOTOMAN robot has led to significantly happier cows and milk yields increased by up to 15 %!

9 Report A/S S.A. Christensen and Co., founded 1938, with headquarters in Denmark, is an international supplier of high-quality milking equipment. The company is present in more than 58 countries by importers with an own distribution network and specially trained technicians. SAC develops and sells equipment and products to increase the quality and effectiveness for milk producers all over the world. Robust industrial robot SAC has fitted this new milking robot with a robust, heavy robot arm, tried and tested in industry, which is able to withstand the aggressive cowshed environment. The powerful HP20 can on its own operate a parallel system with two milking stands, is able to withstand hard work repeatedly day after day, and is also very easy to maintain. 9

10 New A fresh start with the MOTOMAN EA series Besides welding, the newly developed EA1800N can also deal with handling The EA series has now been extended with the MOTO- MAN-EA1800N, a new industrial robot which is ideal for applications such as handling or glueing, as well as for welding. This has extended the range of applications possible with the EA series. With this new EA unit, users benefit from all the positives of the earlier, very successful SSA2000 and EA1900N welding robots. The entire supply of media takes place via the upper arm and wrist of the robot, thereby reducing unpredicatable movements and leading to extension of the usable working range. Thanks to the increased load capacity of 15 kg, the extremely sturdy structure, enhanced linear accuracy and a greater hollow shaft diameter in the T and R axes, the area of application of this 6-axis unit is very broad. Steep ramps guarantee users the highest dynamics, optimised working speed and the shortest possible cycle times. The protected supply of media inside the wrist ensures that media is more readily delivered to devices and components. The optimised media supply greatly extends the service lives of the cables and hoses, and completely eliminates the whipping effect of conventional media packs. In addition, the number of robots in the production cells can be considerably increased. Interference-free movements permit synchronous (cooperating) working for a number of robots in the smallest of spaces. MOTOMAN-EA1800N Number of controlled axis: 6 Maximum payload: Repeatability: Max. working range: Weight: Power requirements: 15 kg ± 0,08 mm R = mm 380 kg 5,0 KVA 10 The areas of application of the EA series are extended thanks to the MOTOMAN-EA1800N. This robot is outstanding owing to its integrated media supply via the upper arm and wrist. Adavantages with the MOTOMAN-EA1800N Load capacity increased to 15 kg Extended maximum working range of 1,807 mm Improved motion control Unparalleled dynamics Optimised speed Integrated media supply via upper arm and wrist Media readily delivered to devices and components Suitable for both welding and handling Offline = Online Compact robot arrangement in the smallest of spaces Long media pack life Previously unachievable availability thanks to low mechanical stresses Shorter programming time (independently of the media pack) Maintenance expenditure minimised

11 New Shelf-type robots for use with low, medium, high and extreme (heavy) loads MOTOMAN-UP50RN-35 Number of controlled axis: 6 Maximum payload: Repeatability: Max. working range: Weight: Power requirements: 35 kg ± 0,07 mm R = mm 600 kg 5,0 KVA The MOTOMAN-ES200RN-120 weighs just 1,560 kg thanks to numerous measures implemented to optimise its weight. Its high travelling speeds reduce the opening time of the tool to a minimum. Visitors to the Gifa 2007 trade fair in Düsseldorf were able to admire this powerful robot in action. An extensive selection of shelf-type robots from MOTOMAN are available to users in the foundry industry and for forging. The five types of robot can be used with die-casting machinery for loading and unloading, or for subsequent complex processing. In addition, these robots can be used in the plastics industry for operating presses and for general handling of materials. These five shelf-mounted robots are particularly impressive thanks to their low weight and their various reaches and working ranges. They each have a payload capacity of between 35 and 200 kg. At the same time, when designing these robots the developers have placed a lot of emphasis on the familiar MOTOMAN slim wrist. The slim arm facilitates entry into small working areas. In practice, this means that the die-casting machine tool has to be opened for a shorter time, resulting in savings in cycle times for users. Advantages of the MOTOMAN-ES200RN-120 Downwards reach (e.g. for loading and unloading machines): 2,798 mm Max. working range: 4,004 mm Low weight of 1,560 kg Integrated hose pack guide Complex gripper exchange system Extremely high travelling speeds Reduction of tool opening time to a minimum Possible applications, such as the loading and unloading of: Die-casting machinery Presses Plastic injection moulding machinery General material handling Five impressive shelf-type robots: Max. load capacity Max. working range Weight MOTOMAN-UP50RN kg mm 600 kg MOTOMAN-ES165RN 165 kg mm kg MOTOMAN-ES200RN 200 kg mm kg MOTOMAN-ES200RN kg mm kg MOTOMAN-ES200RN-120S 120 kg mm kg 11

12 New Synchroweld perfect interaction of robot and welding system SKS Welding Systems and MOTOMAN robotec collaborated in the development of the Synchroweld innovative system solution. Synchroweld is their joint response to the demands of the automotive industry and its supplier industries for a welding process with process capability. The energy input per unit length has not always been regarded as an important parameter in the majority of supplier industry applications. However, as the amount of close-grained steel, duplex steel and high tensile steel increases in the axle area or in the high-temperature area of exhaust systems and for thin sheets, energy input per unit length will become an important parameter. Energy input per unit length describes the energy that is introduced into a component per unit of length or to be more specific: the heat input in a component. Synchroweld unites robot and welding machine to a procedural entity. This combination is made possible because thanks to Synchroweld the welding machine now for the first time knows the actual welding speed, i.e. the TCP speed of the robot and its external axes. The speed information is now directly processed in the welding machine control. Synchroweld opens up new welding process options. Synchroweld allows the energy input per unit length to be kept constant thus ensuring that heat is introduced into the component evenly. The benefits of Synchroweld in general are that it reduces the amount of warping and keeps structural modifications to a minimum, even in the case of standard welding applications. Welding without Synchroweld Welding with Synchroweld Optimum welding result Base material = Welding consumable = Inert gas = 97,5% Ar, 2,5% CO 2 Sheet thickness t = 1,5 mm Welding speed v = 2,2 m/min Base material = Welding consumable = Weld seam pictures Inert gas = 97,5% Ar, 2,5% CO Synchroweld weld seam 2 from the robot s Sheet thickness t = 1,5 mm pictures with homogenous seam appearance reorientation points Welding speed v = 2,2 m/min and constant penetration 12 Welding without Synchroweld: Weld seam pictures 1 / 2 / 4 and 5 are of the fillet weld shown above at the robot reorientation points. Penetration is strongest at these four points and it even shows a burnthrough right down to the tool. The robot adapts its speed in the burner reorientation area and slows down on sharp curves. However, the welding parameters of the welding system remain constant. Because of this, too much energy is introduced into the component at these 4 points, which causes the uneven seam appearance or the burnthrough. Previously, welding parameters and the associated welding speeds had to be determined using complicated methods in these problematic locations. These points are exactly where Synchroweld makes use of its optimisation potential (see: weld seam pictures on the right side). Welding with Synchroweld: The welding parameters are matched automatically to the actual TCP speed of the robot or the complete system, consisting of robot and external axes. If the robot slows down at the reorientation points or on sharp curves, the welding parameters are synchronised at the same time. Result: A constant energy input per unit length is introduced in the component. The result is homogeneous, constant penetration and identical appearance at all points of the weld seam.

13 New Event The advantages of Synchroweld Optimum welding results with constant weld penetration and identical appearance at all points of the weld seam (even at the torch reorientation points) Continuous energy input per unit length the energy provided in unit time remains constant during welding Process optimisation visualisation of the actual TCP speed in the measurements means a process can be optimised Work made easier and time saved even with complicated weld seam geometries only one welding program and one welding speed setting is required Welding data documentation the actual values and the actual welding speed are documented as well as the nominal settings RWDE monitor all relevant values are displayed on the MOTOMAN Teachbox monitor Applications Synchroweld, the principle of constant energy input per unit length, can be applied fo the welding of: Outline parts high strength close Grained and duplex steels Reduced-heat welding of thin sheets, because concentrated thermal overheating is avoided or rather the energy input per unit length con be adjusted selectively! Process optimisation with Synchroweld Another advantage of Synchroweld is cycle time reduction. The recorded measurements show the user the speed trend. This means that specific reprogramming can be carried out for the locations of a seam at which speed drops are detected, thus increasing the speed Wire feed speed Voltage Current Welding speed Energy input per unit length Synchroweld presentation in the Landstuhl Stadthalle : A roaring success Following its first appearance at the AUTOMATICA 2006 trade fair in Munich, the Synchroweld has now been presented to a large group of people from the automotive industry and its supplier industries. SKS Welding Systems in co-operation with MOTOMAN robotec explained the benefits of the Synchroweld system solution in the course of a two-day symposium. The visitors were informed about the joint development from SKS Welding Systems and MOTOMAN robotec in lectures and product presentations that were clear and informative. Many visits took the opportunity of seeing the Synchroweld in operation on the following day. The new SKS developments in the field of laser welding also attracted a lot of attention here. With almost 250 visitors from the trade, the interest shown on the Synchroweld exceeded all expectations. We would like to thank all customers and partners for their visit. Combined theory and praxis: During the two days the visitors could immediately implement what they had heard in the testing area. 13

14 System partner Robot concept sets new standards Automated programming for efficient painting of small batch sizes Fully automated painting of small runs and large components geometry variants is no longer a problem. Because the robot programs necessary for the process, which are often complex, are now created by means of image recognition directly in cycle the run fully automatically! The MOTOMAN-PX2900. The robust design and high quality of this unit ensure outstanding economy while at the same time being as environmentally friendly as possible. 14 The painting of small batch sizes and individual components has always been something that can only be done by hand. Mostly, the programming effort does not warrant the painting results. Moreover, the large range of variants that you find as a rule with subcontract painting usually results in very high reconfiguration costs. The logical consequence of this is cost-intensive, universal automatic painting units resulting in high overspray or additional layers being applied at the weekends. However, it is not unusual for reliable product data to be missing, making it difficult to precisely control the program. And so to date, clients and contractors alike had to settle for an unpalatable compromise to give up on reproducible quality in favour of production at a reasonable cost. A concept designed especially for small batch sizes by robot manufacturer MOTO- MAN robotec (Allershausen) in cooperation with LacTec (Rodgau), the system supplier for painting technology, paves the way for a new era in painting by robots. Whether or not the subcontract painter has special knowledge of robot programming is immaterial. Now even individual components with complex geometries can be painted quickly, economically and precisely. And at the heart of all this is the MOTOMAN-PX2900-F10. This is a painting robot which stands out from the crowd thanks to its extreme dynamics, its large range (up to 2,900 mm) and above all thanks to its very special process arm with a hollow wrist. Batch size 1 However, the basis for fully automatic painting of small batches, known as batch size 1, is actually a long way ahead of the actual painting process. As soon as the workpieces have been suspended on the carrier, they pass through a linear scan Simulation of a painting process. field. As part of this inline concept, a number of cameras detect the component geometries from which a 3D model of the workpiece to be painted is generated for each image processed. When this is done, the position of the component in the area is determined for precise recognition. From the overall raw data (point cloud), an area model is then generated which extracts the relevant features and defines the painting parameters for the application. From the underlying expert knowledge, the system then determines the painting cycles and even calculates collision-free movements of the robot. In this way, the requisite program is compiled fully automatically. Finally, the MOTOMAN painting robot executes the painting with no manual intervention. The important thing here, says Ralf Deparade, project manager at LacTec, is that we also generate a model which precisely shows the painting cycles. Workpieces with extremely complex geometries recesses, nooks and crannies considerably impair the scanning process. And it is not unusual for models to be produced which include holes and uneven surfaces which are undefinable for the robot. Such models lead to situations where there is no element present at these locations for the software, and so no pass can be made over this area. The result: the robot switches off. In these instances, the operator has the option of intervening manually of subsequently processing the half-finished scans in a CAD system and supplementing

15 System partner New Virtual representation of a simulation. them. If no scan is possible, the semiautomatic offline variant is available instead. 3D CAD data in a database is used for this. This variant provides a precise view of the workpiece including points missing from the scan data, which are as important for the completion of the program as the 3D image. To make the system run efficiently, an open interface to the robot control has to be maintained in order to reproduce the results of the camera sensors and the expert system as paint on the component. Special control The MOTOMAN painting robot with its special YASKAWA control is all but perfect for this process. In this respect, above all the high axis speed and the axis acceleration of the PX2900-F10 closely correspond to what we need, explains Tilo Dobmeier, sales engineer working for robot manufacturer MOTOMAN in Allershausen. Another crucial advantage of the painting process rests with the qualities of the process arm, which can adapt to all the techniques necessary for painting thanks to its large working envelope. Moreover, the wrist of the robot is hollow and completely contain the supply hoses. According to Dobmeier: This considerably reduces the production risk associated with an undefined hose pack which has to be fitted to the outside. Optimum for painting subcontractors The main people to benefit from this technology are the painting subcontractors, whose product ranges are broad and include some extremely small batch sizes; as well as manufacturers of system modules which have to be laminated in any combination (such as engine-transmission units). High production capacity utilisation is required for this solution to be economical, with at least 2-shift operation for the fully automatic scanner system. In the case of the variant which uses existing 3D data, the investment will pay off even earlier. What we are finding here, says the MOTOMAN salesman, is optimisation of the automated painting process when painting small runs. In this respect, we have managed to reduce the amount of paint used and the amount of additional effort required. Contact: LacTec, Gesellschaft für moderne Lackiertechnik mbh Otto-Hahn-Straße 6 8 DE Rodgau Tel. +49 (0) Fax +49 (0) Slimarm robots ensure optimum performance! Three new PX series Slimarm ( Hollow ) models are now available to users: PX1750-F50, PX2050-F50 and PX2850-F50. The characteristic feature of these units is their slim, hollow upper arm ( Slimarm ), which allows paint to be applied even to the farthest reaches of the bodywork such as the access steps while maintaining excellent quality. The entire media supply takes place via the upper arm of the robot, thereby reducing the risk of interference and increasing the working range. These robots are a further development of the current PX series, with its models MOTO- MAN-PX1450, -PX1850, -PX2050, -PX2750 and -PX2850. They are 100 % compatible with these and have identical controllers. Using identical components in the controls means that fewer replacement parts are required. These modern Slimarm robots close the gap left by the smaller paint robots with hollow wrists and with the aid of the hollow arm also move the hose pack even further away from the production process. The MOTOMAN- PX2050-F50, equipped with a hollow type wrist. Advantages of the Slimarm robots Three variants available Identical models (easily exchangeable in preplanning) Powerful, with a 15 kg payload capacity Ideally suited to opening of boot lids/bonnets as well Direct fitting of painting technology on the robots Slim robot arm minimises interference Can access narrow workpieces Internal hose pack up to the upper arm, with particularly large internal diameter: 50 mm Max. working range: 1,757 mm to 2,833 mm 15

16 System partner Fast labelling of high stacks We encounter organic fibres in all their forms in many areas of our day-to-day lives without even realising: from foods to technical products, from pharmaceuticals to innovative plastics. J. Rettenmaier & Söhne is dedicated to research, development and production concerning these organic fibres. Stacks of up to three pallets are provided with up to 18 labels within a minute by the MOTOMAN-HP20-6. However, the automation process described below does not start during manufacture, but later; during packing and picking of the finished products. Once the products have been packed in sacks and stacked on pallets, the stacks are then stabilised using wrapping film, after which labels have to be applied fully automatically to the stacks of pallets ready for dispatch. Flexible automation solution A MOTOMAN-HP20-6, with a reach of 1,915 mm and a load capacity of 6 kg, is used in this system. This ensures a repeatability better than 0.06 mm. The NX100 control unit is used to control the robot. With its extremely small internal circular motion (just 512 mm), this robot has a very large active working range. The labels to be applied contain information on the product, customer, weight, stack height, etc. and/or customer-specific information. The logistics label is printed in accordance with the EAN128 regulation. The pallets run randomly to the labelling station from five palletising lines. The labels are collected from a label printer with a dispenser function by the robot and stuck to the relevant pallet positions. A vacuum tool is used to pick up the labels. Inaccuracies on the pallet stack are detected by means of an ultrasound sensor and offset fully automatically to the programmed position. In addition, the vacuum plate is spring mounted. Once the label has been applied, the robot turns the tool through 90 degrees. An integrated laser scanner detects the presence of the label and verifies the content of the barcode. Up to 18 labels can be applied to the pallet stack, according to what the customer requires. Only 60 seconds are available to the robot for this. As soon as a production task is recorded in the production planning system, the data is transmitted to the BBK 16 And this is where BBK Etikettier- und Sondermaschinenbau GmbH from Beerfelden come into play. BBK has developed over more than 20 years into a company which creates complete solutions, from labelling technology and special software for printing, automation and visualisation tasks to special machine construction. This places BBK in a position to be able to offer a one-stop shop for complete production solutions for logistics. BBK supplies a wide variety of industries with its systems and the relevant consumables: the pharmaceutical, chemical, medical, automotive, cosmetic, drinks, foods, entertainment and packaging industries, for instance. The MOTOMAN- HP20-6 gets the labels from a printer with a dispenser function. An ultrasound sensor and barcode scanner are also integrated into the gripper tool.

17 System partner From simulation with MOTOSIM EG to the 3D system layout to the finished cell. LabelsPlatform3 automation software. The preceding wrapping station transmits the line information. The software fully automatically configures the print unit and the laser barcode scanner on the robot tool. For this, the label positions specific to each product are stored in the LabelsPlatform3 database manager. MOTOSIM EG simulation tool The MOTOSIM EG simulation tool was used as early as the tender stage for the automation system so as to select the correct type of robot, to find the optimum robot position in relation to the pallets and to optimise the tool for applying the labels for each individual application. Compliance with the required cycle time is also checked and assured at this stage. When the tender was submitted to J. Rettenmaier & Söhne, the finished simulation film could be presented as well. This gave the customer the security of knowing, even at this phase, that the system would comply with the required technical key data. This made a very significant contribution to the customer s decision to order the robot cell from BBK. Good cooperation For just under two years now, BBK has been using industrial robots to apply labels to a very wide variety of drums and workpieces. In this application, the flexibility offered by an industrial robot in respect of the special solutions previously used exclusively is very much appreciated, as is the simple programming of the MOTOMAN NX100 control unit and its uncomplicated, convenient connection to the system peripherals. Alexander Beck, assistant to the Managing Director and responsible for the robot projects at BBK, summarised the situation as follows: The decisive factors for the selection of MOTOMAN industrial robots were the high travelling speeds, the simple robot programming and the extensive product range offered by MOTOMAN. Good, straightforward cooperation with the robot manufacturer is very important to us when it comes to the implementation of complex projects. We have got to know MOTOMAN robotec and found them to be a reliable partner. We will be implementing more projects together. Contact: BBK Etikettier- und Sondermaschinenbau GmbH Eichenstraße 38 a DE Beerfelden-Airlenbach Tel. +49 (0) Fax +49 (0)

18 System partner Cooperating robots guarantee high quality for precision deburring 18 WMS-engineering GmbH, founded in 1994, employs some 40 staff and specialises in the mechanical deburring of various workpieces and materials. WMS came into being in the early 1990s from SIG Robotics, based in Neuhausen in Switzerland, and at that time developed special deburring solutions in cooperation with MOTOMAN robotec GmbH. In the meantime, the range of products covered by the company extended from the trimming of large, rough workpieces to the precision deburring of medium to small, complex workpieces. Alongside a broad range of The compact, modular cell structure is standardised to a large extent. Customers have a range of standard variants to choose from, even for feeding and storing workpieces. standardised deburring cells, WMS-engineering GmbH also supplies individual turnkey automation solutions. The system concept The clientele of WMS-engineering GmbH mainly include automotive suppliers. This means that very stringent demands are made of deburring with consistent, reproducible quality. The company focuses on the highly diverse range of part variants to be deburred, particularly in the case of small batch sizes. In this respect, WMS-engineering GmbH created a new, standardised system concept which can handle a wide variety of parts weighing from 300 g to 3 kg. WMS-engineering GmbH now offers four basic variants for tool weights of up to 3 kg, up to 10 kg, up to 30 kg and up to 100 kg. Depending on the application, the compact cells can be equipped with a wide variety of deburring tools and additional modules such as knives, printing, washing and so forth. In addition, various options are available for feeding and removing various parts according to customer requirements. The cell type shown is used mostly for working on components such as rotors, flanges, hydrolock drives and lots more besides. Parts are subject to precision deburring. The difference between precision deburring and normal deburring is that the edges are defined and worked to the required tolerances. This defined quality is absolutely crucial to customers of WMS-engineering GmbH. Three criteria form the decisive factor for this high degree of quality in the deburring process, according to Stephan von Schneyder, Managing Director of WMS-engineering GmbH: 1. The robot system, along with overall SPS control, including visualisation, 2. The deburring tools developed by WMS-engineering GmbH, and 3. the process knowhow built up by WMS-engineering GmbH over many years. Twin robot solution WMS-engineering decided to go for two MOTOMAN- HP5s, integrated to form a Twin system. In other words, the system consists of two robots which work fully synchronously with a shared controller. The industrial robot enters the area of the other robot with no problems and no collisions. This is because one robot calculates the working area of the other and does not have to query the individual

19 System partner Fair The Twin principle: in this system, the two MOTOMAN-HP5s are controlled by a single shared controller. The patented, flexible milling spindle from WMS for the controlled removal of edge burrs. positions, so resulting in a faster system cycle time. This means greater system safety while taking up less space, as the system requires just one NX100 control cabinet. All that is required is a small cabinet for the second robot s additional servo pack. That said, though, another major advantage of this system can be seen when looking at costs. This is because investment in a Twin solution using two robots and all their peripherals works out at just 1.5 times the cost of two individual robots, instead of having to pay for two complete systems. And not much space is required, says Stephan von Schneyder. Peak precision, top individuality Another positive of this system is its modular structure, which is standardised to a large extent. A range of standard variants is available to choose from for feeding and storing parts. Components are added via pallets, vibratory feeders or even a portal, so ensuring the correct shape and position. If the part to be worked is accepted, it is gripped by the MOTOMAN-HP5 and moved past the flexible deburring tool. A clean, defined deburring image is generated - for this, the rigidity and accuracy of the robot are very important. After deburring, the finished parts are fed in a controlled manner to the next production process. With this concept, the automation system is always customised to suit the requirement at the time despite the variuos options and the individual requirements of the customer. And so customers have a wide range of options to choose from with WMS-engineering GmbH. Contact: WMS-engineering GmbH Jahnstraße1 DE Klettgau-Griessen Tel. +49 (0) Fax +49 (0) Successful appearance at Antwerpen, 16. to Welding Week 2007 MOTOMAN Benelux did a great job with style in Belgium. The attractive trade fair stand was praised highly by visitors and fellow exhibitors alike. The professionalism demonstrated on the stand led to lots of very promising contacts and convinced visitors of MOTOMAN's welding expertise. 19

20 Fair Ideal robots for every assembly and handling application, and the European premiere of the smallest 6-axis robot in the MOTOMAN product range Stuttgart, 24. to MOTOMAN, together with seven strong system partners, exhibited some interesting applications using a wide variety of robot kinematics at the MOTEK exhibition in Stuttgart, over an area covering more than 200 square metres. The last time the company participated in MOTEK, the new robot types and kinematics Scara, Snake and Dual-Arm were the primary points of focus, so this year the emphasis was on practical applications of these models. The HP3J, the smallest robot from the HP3 range, was presented for the first time in Europe on stand 7510 in Hall 7. The HP3J is characterised by its compact design, its low weight and its load capacity of 3 kg at a maximum working range of 532 mm.this robot is operated using the tried and tested NXC100 control unit. The Scara robots, exhibited for the first time last year, have in the meantime been installed in a wide and diverse range of applications. In this respect, some very interesting applications have come to light in which the typical MOTOMAN multi-robot functionality brings about clear benefits in terms of solutions and the amount of effort and expense invested. One of the trade fair exhibits demonstrated these advantages quite impressively; consisting of two Scara robots, one 6-axis robot and an external rotation axis, all controlled synchronously by a single NX100 control unit European premiere in Stuttgart of the HP3J, the smallest robot in the HP3 range. The advantages of multi-robot functionality were demonstrated by two Scara robots, one 6-axis robot and an external rotation axis. Wolfgang Bott GmbH & Co. KG, Mössingen: Representative of Omil Greifsysteme, Omil gripper technology was demonstrated on an HP3L. CeraCon GmbH (Weikersheim) & PlasmaTreat GmbH (Steinhagen): The two companies demonstrated jointly in one exhibit surface pretreatment with subsequent application of a 1-component sealant to a workpiece, immediately after taking them out of a plastics injection moulding machine using an HP6. 5 DMG Automation, Hüfingen: Under a new name, but with an exhibit demonstrating a well known application, DMG Automation GmbH (formerly WKZ Werkzeugmaschinen GmbH) presented an HP20 in a standard cell for automation of a DMG machine. 6 EGS Automatisierungstechnik GmbH, Blumberg: EGS demonstrated its many years of expertise in the integration of MOTOMAN industrial robots by means of an application using an HP20. 7 itec Automation und Laser AG, Berlin: This company demonstrated one of its own machines for laser cutting - an HP3 handled loading and unloading. 8 projekt Automation GmbH, Köln: A light-hearted application emphasised the opportunities offered by modern robot technology. Three robots played boules with one another! This system used two HP3Ls and one HP20, supported by the relevant sensors.

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