FANUC Robotics Demonstrates Compact and Flexible Arc Welding at Fabtech 2011
FANUC Robotics America Corporation
FANUC Robotics America will demonstrate compact and flexible arc welding with a DualARM controlled R-1000iA/80F high-speed, compact robot and ARC Mate 100iC welding robot during Fabtech 2011, Nov. 14-17, held at McCormick Center in Chicago, booth #5928.
At the show, the R-1000iA/80F transfers an exhaust manifold part (with a weld coupon attached) to the DCS load zone where an operator safely exchanges the welded coupon. Dual Check Safety (DCS) speed and position check software restricts the motion travel of the robots to the exact area specified in the operator load safety zone. After the weld coupon is exchanged, the operator then signals the system to start production. The ARC Mate 100iC robot with ServoTorch (SVT) works in coordinated motion to simulate welding and then performs live welding on a weld coupon. The R-1000iA/80F transfers the part and weld coupon to the load safety zone where the operator safely exchanges the welded coupon with a new part, and the cycle repeats. The robots use iRVision Weld Tip Inspection to verify the condition of the welding tips.
“We’re showcasing our advanced ArcTool feature which monitors the welds, said Mike Sharpe, Materials Joining Segment, FANUC Robotics America. “The Lincoln Electric Power Wave® R350, provides an extremely stable arc response for optimized performance in robotic arc welding. In addition, the ARC Mate 100iC robot with SVT ensures low-spatter arc starting while providing stable wire feed control through the FANUC Servo motor and wrist-mounted wire feed drive.
“iRVisionTip Inspection software verifies that the welding tip is in good condition, and properly aligned to help arc and spot welding customers reduce product issues and scrap/rework costs caused by poor tip conditions,” added Sharpe.
R-1000iA Intelligent Robot
The R-1000iA/80F has an 80kg payload, and the R-1000iA/100F has a 100kg payload. Both robots feature a slim design, allowing customers to reduce the overall size of their automation system by using more robots in each work cell, or making work cells with a single robot significantly smaller. The narrow footprint of the R-1000iA also allows for easy access to adjacent robots, fixtures and work pieces. The R-1000iA can be floor or invert mounted, and has a large work envelope.
R-1000iA Features and Benefits
· Very small footprint reduces size of automation system.
· High-density installations allow work to be completed in fewer stations.
· Single-robot work cells can be designed to fit in tight spaces.
· High-speed operation minimizes robot cycle times.
· Simple serial-link configuration with large operating envelope (including rear and downward side).
· Upright or invert mounting accommodates a wide range of work areas.
· Substantial wrist load ratings support the latest compact servo weld guns.
· IP67 rated wrist allows operation in wet conditions.
· Right sized for 80kg or 100kg applications reduces energy usage.
· Optional Solution Arm dressout package with internal cable routing for spot welding processes.
· The latest robot controller offers a variety of intelligent functions including iRVision, Force Sensing, ROBOGUIDE, Robot Link, and Collision Guard.
iRVisionTip Inspection Features and Benefits
iRVisionTip Inspection error proofs weld tips to reduce product issues and scrap/rework costs caused by poor tip conditions. It offers a variety of advantages for arc and spot welding, including:
· Measures contact tip wear
· Maintains an accurate tool center point (TCP)
· Calculates maintenance cycle
· Improves weld quality
· Measures tip wear
· Measures and verifies alignment
· Verifies tip dress
· Verifies new cap and cap type
ARC Mate 100iC intelligent welding robot
FANUC Robotics’ six-axis, ARC Mate 100iC intelligent welding robot features a compact design, class-leading operation efficiency, speed, load capacity, and enhanced performance for welding parts of all shapes and sizes.
Compared to traditional dress packages, which are mounted externally on the robot’s arm, the ARC Mate 100iC’s internal routing allows the dress package to follow the motion range of the robot, simplifying programming and eliminating the worries of bending, snagging or breaking cables.
FANUC Force Sensing
FANUC Force Sensors are fully integrated into the CPU of every FANUC controller. Available in four models ranging from 15kg to 250kg, FANUC Force Sensors provide the most robust and reliable solutions in the market. A single source solution developed and supported by FANUC, the FANUC Force Sensors offer easy setup and operation for factory operations requiring part matching, meshing, inserting, force loading and deburring.
FANUC’s iRVision is a truly integrated, plug-and-go vision system that runs on the standard CPU of every FANUC controller without any additional hardware. A single source solution developed and supported by FANUC, iRVision offers easy setup and operation for factory environments requiring 2D and 3D guidance, error proofing, visual tracking, and quality control – all with FANUC’s world-renowned reliability.
Dual Check Safety (DCS) Speed and Position Check Software
Prior to the application of safety rated robot software, all safeguarding of the robot needed to be external, and required a safety rated limit switch or cam system, safety rated area scanners, or other devices to limit robot travel or enhance protection. DCS safety rated robot software allows the safety design of the robot system to use the robot itself for some of the safety functions.
The most significant benefit of DCS Speed and Position Check is in applications where the travel of the robot needs to be restricted due to floor space or process limits that are less than the full reach of the robot. Restricting the robot motion in Cartesian space means the robot can be restrained to exactly the area in which it works; something that is not possible with the current systems that limit robot motion externally using limit switches.
“By moving some of the safety functions to within the robot, customers will realize significant savings in floor space, flexibility in system layout, reduced hardware costs, and improved reliability,” said Claude Dinsmoor, general manager, material handling segment, FANUC Robotics.
In addition, safe "zones" can be enabled and disabled from an external source such as a safety PLC (based on the cell design). Designing a system with multiple zones and appropriate guarding means an operator can safely enter and leave the workspace of the robot.
“This streamlines the design of robot cells because it prevents the robot from entering the load area when an operator is present,” added Dinsmoor. This type of application is possible with existing technology, but it is typically difficult to setup, expensive to implement, and requires more floor space than a system using DCS.”
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 29 years of success, FANUC Robotics maintains its position as the leading robotics company in the Americas. Over 100,000 FANUC robots are installed in the Americas, and 250,000 worldwide. A subsidiary of FANUC Corporation in Japan, the company is headquartered in Detroit, and has facilities in Chicago; Los Angeles; Charlotte; Cincinnati; Toronto; Aguascalientes, Mexico; and Sao Paulo, Brazil.