Page 35 - MetalForming January 2020

Typical layout restrictions when automating existing lines relate to long interpress distances or narrow die clear- ances, according to Roda.
“In such cases, the use of external linear or rotational additional-axis robots, such
as ABB’s IRB7600FX or IRB7600RX models, and the selection of the right end-of-
arm tooling play key roles in obtaining top performance of installed press-line assets,” he
says. “Robots can adapt easily
to a range of production vari-
ations such as double, triple
or quadruple picks-and-drops, increased distance between
parts during press-to-press transfer, or the extraction of semifinished parts prior to the last press in a line.”
Robots also provide an ideal solu- tion for handling of smaller parts tra- ditionally not associated with press automation.
“Applications include back covers for flat-panel televisions, air-condi- tioner components and other parts often produced on smaller press lines,” says Roda. “Instead of larger automo- tive panels produced at line speeds of 10 to 14 strokes/min., these parts move at 18 to 20 strokes/min. or faster, and robots readily handle those types of parts and line speeds.”
Another application for robotic part handling: nontraditional part flows.
“In some cases, such as in a press cell, the same robot performs perhaps three different tasks,” Roda explains. “A robot may be responsible for inter- nal transfer of parts between the stages inside of the press, and later on must transfer these part to a pol- ishing center or welding operation. Such nonlinear applications point to the flexibility of robotic automation. The robotic-handling possibilities here are endless.”
Beyond the robots themselves, metal formers also may consider inclu- sion of related part-handling compo- nents when automating operations. Where part-transfer equipment once
existing production. Integra- tors can communicate with customers and involve them closely through all phases of robot integration, from design through commissioning, according to ABB officials, resulting in more quickly designed systems and higher productivity. Built on the ABB Virtual Controller, an exact copy of the real software that runs robots in production, RobotStudio reportedly ensures that everything in the virtual world works exactly how it will in the real world, by using real robot programs and configu- ration files identical to those
used on the shop floor. Realistic graph- ics display tooling, movements and throughput, enabling users to verify tooling, cycle times, work envelopes and product throughput before any construction begins.
Such software affords the opportu- nity to test multiple configurations on a PC, according to ABB officials, and new products can be added to existing lines in the virtual programming envi- ronment without disturbing existing production.
“Years ago, robot integration meant physically being at the press and in front of the robots at a stamper’s facility to determine the correct location and to conduct robot programming,” Roda says. “We needed to be connected to the real robot and the actual manu- facturing equipment. Today, in advance, we prepare PLC and robot programs as well as safety features, and test everything via simulation tools. Then, it’s only a matter of loading the new programs into the robot onsite.
“In one case,” he continues, “I remember delivering a robot on a Mon- day morning, and performing mechan- ical work such as installing the robot stand, and connecting the cables, on a Monday afternoon and Tuesday morning. By Tuesday afternoon we pro- grammed the first parts, and conducted the first physical tryouts on Wednesday morning.”
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Today’s software programs and graphical interfaces more quickly and easily integrate robots into press-line and related workcell applications, and also help answer skilled-labor challenges.
employed “spiders,” as Roda calls them, referring to perhaps 2 by 3-m frames with suction cups to transport panels, today, robots make use of short “anten- nae,” or arms with suction cups on the ends. These structures also may be constructed of carbon fiber rather than aluminum. Overall, these develop- ments reduce space and weight while providing the same holding capacity, enabling more flexibility in transfer position and speed.
Remote Testing, Simulation Cut Integration Time, Cost
While adding robots to a press line or workcell always will require physical installation of equipment, mechanicals and cabling, the advent of integration software and simulation, along with offline programming, has reduced inte- gration from weeks for small and medi- um-sized projects to only a couple of days in many cases.
Advances in computing power bring the ability to offer sophisticated soft- ware that trials robot integration into press lines and workcells without caus- ing downtime and necessitating time- consuming onsite work, with all of the associated costs. Roda cites ABB’s RobotStudio as an example. The com- puter-based programming system, showcased by ABB at FABTECH 2019, allows programming to be performed on a computer without disturbing