Yaskawa Motoman offers manufacturers a wide range of robotic solutions for cutting and material removal applications. Our robots have been used extensively in laser, plasma, waterjet and oxy-fuel cutting applications, as well as grinding, polishing and finishing.
Many robots are not designed for the rigors of grinding, polishing, buffing or other material removal tasks that use the robot to manipulate a material removal tool (wire brush, sand paper, knife) over the part surface or contours. In addition to an extensive line of six-axis general-purpose robots, Yaskawa Motoman has a robust, application-specific DX1350 robot designed with the rigidity needed for material removal applications. In order to ensure constant surface pressure on contoured products, an active force sensing device is often used to optimize the finish on the part and increase efficiency of using abrasive consumables by as much as 10 times!
Robotic material removal systems are often required to perform multiple tasks -- cut and deburr, sand and polish, etc. Two approaches – multiple spindles or spindles that can change media or tools – can be used to perform the various tasks. The method used is generally determined by the process. Experienced Yaskawa Motoman application engineers will help you determine the best approach for your project.
Cutting and Material Removal applications typically consist of multiple operations. While the operations vary with the application, we’ve listed several of the most common operations below.
Presenting parts to robots varies widely from application to application and from part to part. In the past parts needed to be precisely fixtured so that the part is always in the same position and orientation. This is expensive, time consuming and doesn’t allow for flexibility when the part type or size changes.
Our MotoSight™ vision products can help locate the parts so that the robot can pick them up precisely and consistently. This includes parts that are loosely fixtured, parts that are presented on a conveyor and in some cases parts in a box or bin.
Grinding applications typically mean bringing parts to a grinder or sander and holding the parts precisely or moving along a specified path. We have a wide range of robots, including the HP250D-200, HP350D, HP500D and HP600D robots for larger parts. These robots have the payload capacity for handling large parts and are a parallel link design, which is very stiff for demanding high pressure grinding applications.
For finishing and polishing applications, the parts are frequently smaller. For these applications, robots from our MH line are a good choice for the task. These high performance, durable robots are ideal for these applications. For part to process tasks with larger parts, the MH215 or MH250 are good choices. For smaller parts or process to part applications, a MH50 or MH165 may be chosen.
For gear deburring, we offer our PerfectEdge™ 2010. This system is designed for precise deburring of gears up to 20” in diameter and 10” tall. These are general guidelines that may differ depending on the specific gear configuration. Other configurations are available to meet specific customer needs.
Trimming and routing are ideal robot applications. Because of the flexibility offered, a robot may be able to tend a machine in addition to the material removal processes. With standard SPI and other flexible interfaces available, machine interfacing becomes easy, allowing quicker startup, debug and programming.
This video demonstrates automatic unloading of an injection molding press. Once the robot has removed the part, it can perform any edge trimming and routing necessary to finish the part completely during the mold cycle. The ultrasonic trimming head can easily cut carpet, headliners, instrument panels, door and other interior auto trim panels. Highly efficient and space saving, this application can replace waterjet cutting.
Many people think of sawing as a material handling application. In cases where the robot loads product into or out of a saw, it certainly has many of the same characteristics. In recent years, we have seen an increase in applications where the robot is manipulating raw material as it is cut by the saw blade. This creative application provides a highly flexible solution for cutting a wide range of materials.
We offer an extensive line of standard robotic positioners for work holding. Our patented MotoMount™ system makes installation easier, improves operation, reduces bearing stress and extends the life of the positioner. All of our positioners can be customized to meet the needs of your application.
We also offer transporters for light and heavy payload robots. MotoSweep™ is a rotational robotic transporter, and MotoRail is a linear robotic transporter.
Programming complex applications in robots can be a tedious task. Applications that require a large number of programmed points are often done using a CAD/CAM system. The geometry data created is used to produce a G-Code output. These G-Code programs can be used by our G-Code Converter software to produce robot programs and reduce a time consuming process to a few minutes. In essence, we are “automating the programming of the the robot.” G-Code Converter software is ideally suited for customers who are working with third-party CAD/CAM expert packages for applications such as material removal, grinding, mold creation, surface finishing or drilling and tapping. It is a productivity enhancement tool for users that have experience with G-Code programming.
Shipping faulty or defective products can be devastating to a business. Machine vision has a long history in part inspection, ensuring consistent and predictable quality. Whether it’s gauging a part, detecting presence of a feature or error proofing, our MotoSight products have all the necessary inspection and data analysis tools for part inspection.
Absolute positioning accuracy is important for path accuracy in high-precision applications and is essential for off-line programming (OLP). Like any mechanical system, robots are built within manufacturing tolerances. These small differences affect the absolute positioning accuracy of the robot. We offer calibration services to improve robot accuracy. Accuracy should not be confused from repeatability as the repeatability of a robot is the precision of the robot to go to the same position time after time. The accuracy of a robot is the precision of a robot to move a given displacement.
Our robots and automation products can be used in a variety of assembly applications resulting in:
- more manufacturing flexibility to produce a wider range products with faster time-to-market
- faster changeover times, increased system uptime and asset utilization
- increased product quality with predictable results with error checking and in-line testing
- increased productivity with shorter payback
- optimized workflow designed around your value-added processes, not your fixed automation
- elimination of expensive and dedicated hard automation