Robotics Embedded robotic functionality for packaging machinery

Transcription

1 Robotics Embedded robotic functionality for packaging machinery Robotics_EN_0704 VM

2 Trend Integration of robots into packaging processes Secondary Packaging Production Robotics Primary Packaging

3 3 Robotic functionality is a clear trend in packaging machinery. Now, instead of third party robots and proprietary controllers, OEMs are designing modular machines that are essentially clusters of robot arms synchronized to servo-driven belts. The new designs are replacing conventional infeed, collating, cartoning, case packing as well as end-of-line functions with extremely agile robot modules that are infinitely adjustable to future format changes. ELAU s new IEC conforming PacDrive robotic software library is responsible for enabling this transformation. Not only does the PacDrive automation system eliminate the need for proprietary robot controllers, it allows builders to focus on creating innovative robot arm mechanics without needing to become kinematics experts themselves.

4 Conventional Two different controllers Ethernet, TCP/IP, OPC, ftp, http, SMS, SMTP Robot control Packaging machine control Motion bus Field bus Motion bus Robot In/Out Infeed Dual Belt Conveyor Belt Robot Infeed Dual Belt Conveyor Belt

5 5 While robots offer great flexibility, conventional robots use proprietary controllers that incur added costs for hardware, software, integration, training and support. The robot is a separate system that requires extensive effort to synchronize with the machine controller automating the rest of the packaging process. Robot manufacturers each use their own, non-standardized languages that must be learned. ELAU s solution replaces this proprietary controller and software entirely with a modular software approach that s changing the way packaging machines are designed. Proprietary robot controller Multiple programming languages to learn Extensive synchronization work

6 Innovative Single control system with integrated robot functionality Ethernet, TCP/IP, OPC, ftp, http, SMS, SMTP Scalable PacDrive TM Controller with Motion/Logic Control Field bus: e.g. Profibus DP Motion bus: SERCOS In/Out Infeed Dual Belt Robot Conveyor Belt Robot Grouping Cartoner Integration of multiple machine components in a modular configuration Infeed Dual Belt Conveyor Belt

7 7 In the past, it simply was not possible to control multiple robot arms and dynamic packaging processses in a single controller. Performance table for robot applications That s changed. ELAU s PacDrive automation controller is powerful enough to integrate robotics along with all machine motion, logic, HMI, vision and communications requirements. Best of all, the robotic functions and kinematics reside in an IEC conforming software object library. A single, standardized robotic Function Block simply runs in the same program controlling the rest of the process. That means you can say good bye to supporting proprietary black box robot controllers forever. It also means you ll save on hardware, electrical cabinet and software costs, improve the performance of the entire system, and reduce your overall footprint. Reduced engineering and training Standardized software library replaces proprietary 'black box' robot controllers Fewer interfaces, higher performance A single controller integrates robotics, motion, logic, HMI, vision and communications

8 Standard software Robots integrated as equipment modules MES/ERP Level Line Level Machine Level Secondary Packaging Equipment Module Level 1 Grouping Cartoner EPAS-4 automation toolkit: Integrated robotics Equipment Module Level 2 Infeed Dual Belt Robot Conv. Belt Modular software structure with the PacDrive TM template

9 9 In ELAU s development environment, a preconfigured program structure, or template, promotes best practices in modular software design.using this template, multiple robotic modules can be integrated into the overall project just like any other machine module. Programming is simplified by an extensive library of pre-tested, reusable, IEC-conforming Function Blocks, including the PLCopen motion function blocks. Programmers can parameterize rather than write original code for hundreds of functions, including robotics, which results in consistent and highly maintainable code. Access to all variables also simplifies machine engineering and diagnostics. ELAU s experience implementing robot functions in packaging machines confirms that engineering, commissioning and service tasks can all be significantly reduced as a result. Easy programming and diagnostics with the integrated EPAS-4 automation toolkit including robots Convenient access to all variables No additional software tools Standard-based programming simplifies training

10 Robotics library Powerful and convenient 5 th degree polynomial advanced interpolation Circular Spline Linear Point-to-point VEL monitoring ACC monitoring Move x,y,z u,v,w x y z u v w Robot Kinematics Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Virtual master Move PTP Asynchronous Axis 1 Master encoder Move PTP Asynchronous Axis n

11 11 The robot's trajectory can be easily specified in the form of points in the range of movement. The complex conversion of the Cartesian coordinates into the positions of the individual robot axes is performed automatically and in real time by the PacDrive TM software. z Centrifugal acceleration Resulting acceleration Path acceleration The robot module also includes intelligent online acceleration monitoring at the tool center point (TCP). It can also be used for real-time monitoring of centrifugal force on the product in the robot s gripper, based on mass and acceleration. Intelligent acceleration limitation x The belt tracking function enables the robot to be synchronized with multiple conveyor belts or external master axes. For example, the robot can remove products from one running belt and deposit them on a different belt. Point-to-point Circular Linear Motion functions with or without blending Synchronization of robots with different belts (belt tracking) Standard interpolation types with advanced interpolation functionality Intelligent acceleration monitoring

12 Kinematics All standard kinematics for packaging applications Portal Delta 2 Articulated Scara Gantry Delta 3

13 13 PacDrive TM performs the kinematics for standard robot configurations, including articulated, gantry, delta, SCARA and portal robots in up to 6 dimensions. So, there s no need to become a kinematics expert to embed a robotic equipment module into the machine control system. The developer has a choice of configuring transformation modules for standard kinematics from pre-tested Function Blocks or designing their own intellectual property using ELAU's universal transformation module. ELAU s library provides Function Blocks for each robot type, so they can be easily interchanged with no impact on the rest of the machine control software. Performs all standard robot kinematics: gantry, SCARA, portal, articulated, delta Configurable transformation modules for standard kinematics Universal transformation module for customer-specific kinematics

14 Benefits One system all the benefits at a glance Control of packaging machinery with multiple robot modules in a single controller Reduced engineering effort No 'black box' robot controllers Reduced hardware and software costs No performance-robbing interfaces Simplifed integration Less electrical cabinet spaced required Better synchronization of robotic and packaging processes Standard software for all machine modules including robots Simple programming and diagnostics with the integrated EPAS-4 automation toolkit including robots No additional software tools Simplified training Powerful robotics library Supports all standard robot kinematics: gantry, SCARA, portal, articulated, delta Convenient access to all process variables Modular software structure using the PacDrive TM template

15 15 Pester pac automation Stretch wrapping with integrated pac robot 3 robot cell The pac robot could not have been developed without ELAU's robotics library. Because ELAU covers all the system functions, we can concentrate on our core task, namely product handling in the packaging process, Lorenz Fleschutz, Head of Software Engineering Department Wächter Packautomatik Sorting plant with highly dynamic pick & place robot The ELAU robotic functionality and program structure enabled us to cut our engineering and commissioning workload by around 25%. At the same time, we doubled the picker's output from 30 to 60 transfers per minute, Stefan Wächter, Chief Executive Pester pac automation, PEWO-pack 450 Compact Cavanna Robot-based cartoning machine (including infeed, dual belt, 3 robots, conveyor belt) The ELAU solution means that we can easily integrate several robotic modules into the packaging application. All machine modules are controlled by a single ELAU controller and programmed using a standard software tool, Riccardo Cavanna, Product Development & Customer Relations Director ARC Advisory Group ELAU s robotic library turned out to be something of a quiet revolution A number of packaging machine builders using ELAU s PacDrive TM automation system have taken advantage of the software s modularity to design modular machines with integral robotics. Sal Spada, ARC analyst Author of Integral Robotics Raises Agility and Flexibility of Packaging Machinery Cavanna, Cartesio G35

16 Contact ELAU AG Headquarters Dillberg Marktheidenfeld Germany Phone Fax ELAU North America ELAU Switzerland ELAU UK ELAU BeNeLux Detailed information is available at ELAU Italy ELAU Scandinavia Worldwide in 190 countries ELAU France info@elau.fr Subject to change without notice. All trademarks mentioned in this brochure are the sole property of their owners.