JIMTOF2014. Before repair. Yoshiharu Inaba. Mr. Kiyoshi Sawaki. Mr. Jiro Makino. Dr. Hiroyuki Yoshikawa. Mr. Akihiro Teramachi

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1 2014-Ⅲ Photo of Mt. Fuji viewed with a forest in autumn color taken on November 10, 2014

2 IMTS 2014 IMTS 2014 was held at the McCormick Place Convention Center in Chicago, IL, USA, for a six-day period from September 8 (Mon) through 13 (Sat). The trade show attracted a flock of visitors from day one, with the total attendance reaching 114,147, up 14 percent from the last show in The number of exhibitors increased 45 percent to 2008 companies over the same period. The popularity of the event reflects the booming US economy. The FANUC booth, with a familiar yellow airship balloon floating above it, featured the catch phrase: "Reliable, Predictable, Easy to Repair." The benefits of FANUC's products, such as high reliability, operability and usability, were demonstrated to users in an easy-to-understand manner. To stress the integration of Factory Automation, ROBOTs and ROBOMACHINEs, the exhibit showed the ROBODRILL status display, synchronous operation of the ROBODRILL and top-loader robot using a servo door, and a system consisting of the ROBOSHOT and the Genkotsu-Robot, demonstrating the collaboration between Factory Automation, ROBOTs and ROBOMACHINEs. At IMTS 2014, both the number of CNC units exhibited and the number of robots exhibited, excluding those robots installed at manufacturers' own booths, hit record highs of 829 (FANUC accounted for 58.5 percent) and 208 (FANUC accounted for 82.7 percent), respectively. 2

3 JIMTOF2014 The 27th Japan International Machine Tool Fair (JIMTOF) was held at Tokyo Big Sight from October 30 (Thurs) through November 4 (Tue). With 865 companies from 25 countries participating this year, the event was successful, drawing 136,196 visitors during the six-day period. The FA section exhibited FANUC CNCs, servo motors and laser oscillators - products designed to realize high levels of usability and machining performance. Numerous functions to promote factory automation were presented, attracting the attention of many visitors. In the ROBOT and ROBOMACHINE section, diverse lines of products of both categories were exhibited. In addition, FANUC's unique concept of the integration of Factory Automation, ROBOTs and ROBOMACHINEs was presented and was a focus of much interest. Before repair After repair The Services section showed the services that FANUC provides at more than 230 customer service locations in 45 countries around the world. Many visitors highly praised the "before repair & after repair" exhibit for lifelong maintenance. Many VIPs visited the FANUC booth and saw the latest products. (The photo above shows former Prime Minister Yasuo Fukuda touching the Collaborative Robot.) On the first night of JIMTOF2014, FANUC organized a convivial party. Invited guests delivered congratulatory speeches, and many participants had a good time, enjoying the food and having pleasant conversations. Yoshiharu Inaba President and CEO FANUC Corporation Mr. Kiyoshi Sawaki Director, Industrial Machinery Division, Manufacturing Industries Bureau, Ministry of Economy, Trade and Industry Mr. Jiro Makino Vice Chairman, Japan Machine Tool Builders Association Dr. Hiroyuki Yoshikawa Grand Emeritus Advisor, National Institute of Advanced Industrial Science and Technology Mr. Akihiro Teramachi President and CEO THK Co., Ltd. 3

4 Introduction to New Products and Functions (FA) New product Smart overlap Smart overlap is a function that starts the execution of a subsequent block before the current block ends, reducing the cycle time of machining, and contributing to increasing productivity. Applicable models: Series 30i/31i/32i-MODEL B and Series 0i- MODEL F G00 Overlap G01 Workpiece G00 Program-specified path Overlapping path - An overlap can be provided not only between two rapid traverse (G00) blocks and between a cutting feed (G01) block and a rapid traverse (G00) block, but also between a cutting feed (G01) block and an auxiliary function (M, S, T, or B) block. - Since the machining time reduction screen automatically displays the path error (theoretical value) caused by an overlap at a corner section, it is easy to adjust the amount of overlap. Path error display New product Enhancement in short-time output of the spindle motor and spindle smart load meter Enhancement in short-time output The cutting performance and acceleration/deceleration time of the spindle are mainly determined by the output that the 15kW(S3 15 ) spindle motor can provide in a short time. By enhancing the Acceleration time short-time rated output of the spindle motor, an improvement in the cutting performance and a reduction in the cycle time 100 UP 2.11 sec have been achieved. A spindle smart load meter has also been developed that provides an easy-to-view display of the spindle output status. Both the allowance remaining before the maximum output is reached and the allowance remaining before the continuous rated output is reached can be perceived. Since the meter also displays the time that machining can be continued under the current cutting load conditions, the operator can comfortably make the most of the spindle's performance. Output kw 7.5kW(S3 40 ) 1.59 sec Motor speed(min 1 ) Time seconds Spindle smart load meter Current output (compared to rating) Maximum output (compared to rating) Allowable continuous machining time New product 3-kW CO 2 laser FANUC LASER C3000+-MODEL C optimized for sheetmetal cutting The FANUC LASER C3000i-C is a 3-kW CO2 laser that is optimized for sheet-metal cutting without sacrificing the thick plate cutting performance. With the new 3-kW C3000i-C added to the lineup of the LASER C Series i-model C, which now supports a range of output from 1 kw to 6 kw, users can select a laser oscillator that meets their specific needs. - The laser output and beam quality have been optimized for cutting plates as thick as 1 mm. As a result, sufficient cutting speed and machining quality can be attained for a sheetmetal cutting laser machine. - The highly stable laser output enables the cutting of highgrade stainless steel as well. - The LASER C3000i-C is a high-efficiency high-speed axial flow laser and features a power saving function. High maintainability enabled by longer-life consumable parts and a power failure restart function minimize down time and increase operability. These features make it possible to build a laser cutting system with low running cost. LASER C3000i-MODEL C 4

5 Introduction to New Products and Functions (ROBOT) New function 2D vision sensor function that does not require calibration work A new version of irvision, the built-in vision sensor function for FANUC robots, is now available, that requires no calibration work. In the past, before using a robot with a vision sensor, preparatory work, including the calibration of the camera, was necessary. This new function enables the robot to measure the work area automatically using a camera, completing the settings that were formerly conducted manually to calibrate the camera. Once this is done, the robot automatically moves to above the workpiece and picks it up while making measurements with the camera. The new function minimizes the amount of work involved in the setup of the vision sensor, so that just by following a very simple procedure, a robot system that picks up a workpiece by seeing with a vision sensor can be realized. This function can be utilized to create a simple robot system that does not use a workpiece fixture or any other apparatus, in various robot applications across a vast range of fields. 2D vision sensor that anyone can use with ease New products FANUC Robot M-710+C/12L and M-710+C/45M For the M-710iC Series, highly acclaimed as medium-size handling robots, FANUC has developed and released new models: the long-arm hollow wrist type FANUC Robot M-710iC/12L and the middle-arm type M-710iC/45M. - The M-710iC/12L is a robot with a slim arm and a wide motion range that can carry a weight of up to 12 kg. Since the wrist and J3 arm have a hollow structure, the cabling needed for arc welding and other applications can be run through the arm. This not only enables welding work to be done in a narrow, tangled space but also helps lengthen the service life of cables. Having a long 3.1-meter reach and a wide motion range, this robot is suitable for welding large building equipment and materials, and carrying long objects. - The M-710iC/45M is a robot of the middle arm type that can carry payload of up to 45 kg. Its reach, 1.3 times longer than that of the M-710iC/50, makes this robot suitable for conducting work that requires a wide motion range, such as separating goods in a warehouse or unloading workpieces from a large platform. With the J6 wrist inertia being 1.8 times greater than that of the M-710iC/12L M-710iC/50 and having a wide motion range, it can be used to carry large panels. - The M-710iC Series robots have a full cover structure that prevents the cables and motor from being exposed to the outside. Being dust-proof and water-proof at an IP67 rating level, these robots can be used in various work environments. M-710iC/45M 5

6 Introduction of New Products (ROBOMACHINE) New function Support of high-pressure center through coolant (7 MPa) for the FANUC ROBODRILL α -D+A Series For the high-reliability, high-performance ROBODRILL α -DiA Series, we have developed a center through coolant system capable of withstanding pressures of up to 7 MPa. - The sealing structure and material of the spindle have been improved for the center through coolant system to withstand pressure of up to 7 MPa, and have ample durability to withstand that pressure. - The high-pressure center through coolant system enables non-step peck drilling, as well as peck drilling using a small-diameter drill with a narrow passage, which has formerly been difficult to perform. - A broader range of ROBODRILL applications is now supported in the areas of mold machining and automotive part machining. ROBODRILL α -D21M+A5 Material:SKD11(50HRC) Hole diameter:φ6 Depth:150mm(25D) Non-step drilling Example of peck drilling (cross-section view) New product FANUC ROBOSHOT α -S130+A and α -S220+A We have developed the FANUC ROBOSHOT α-s130ia and α-s220ia, both of which are ideal for molding automotive parts. - The tie bar spacing is the widest in this class of molding machines. Since the vertical and horizontal dimensions are the same, a large metal die can be mounted in any direction desired. - The machine is compact in total length and has a low center of gravity with its height kept flat at the center. This design reduces the installation space required and offers greater workability. - FANUC's latest control unit and its servo technology providing high precision and high reliability enable precise and stable molding. ROBOSHOT α -S130+A ROBOSHOT α -S220+A New function Core joint function for the FANUC ROBOCUT α -C+A Series For the high-reliability, high-performance FANUC ROBOCUT α-cia Series, we have developed a core joint function that holds the slug (core) of a workpiece. - The core joint function holds the slug of a workpiece with brass, a material used in wires. A slight shock given by a hammer drops the slug, significantly reducing the work time. - When the core joint function is used, automatic wire feeding is required in the machining groove at the time of wire cutting. For the ROBOCUT, we have also developed a tapered cutting point wire feed function that enables automatic wire feeding even in a tapered machining groove. - The new function is effective for die molding and achieves a high machine operability rate. ROBOCUT α -C600+A Affixed with brass Example of an application of the core joint function 6

7 Acquisition of Land for a New Factory On September 2 (Tue), FANUC signed a letter of intent with the Tochigi Prefectural Government regarding the acquisition of land for a new factory in the prefecture for the purpose of increasing the capacity to produce its main products including CNCs, servo motors and servo amplifiers. Information on the acquisition of land 1. Site: Mibu-Hanyuda Industrial Park in Mibu-machi, Shimotsuga-gun, Tochigi Prefecture 2. Area of the land to be purchased: Approx ha 3. Current owner of the land: Tochigi Prefectural Government 4. Purchase period: From September 2014 Pursuant to this letter of intent, we acquired approximately 37.7 ha of developed land on September 19 (Fri). The remaining pieces of land will be purchased as soon as they are developed. This fourth manufacturing base, following the factory at headquarters, Tsukuba Factory (Chikusei-shi, Ibaraki Prefecture) and Hayato Factory (Kirishima-shi, Kagoshima Prefecture), has been named Mibu Factory. Preparations are now underway to put the factory into operation two years later. The factory will become a cutting-edge robotized factory which consolidates FANUC's technological strengths. Bird s-eye view of the site of Mibu Factory (photo provided by the Public Enterprise Bureau of the Tochigi Prefectural Government) CNCs, servo motors and servo amplifiers to be produced at the new factory 7

8 Third Milling Factory Machining factory using robot cells At the Third Milling Factory, robot parts are machined. A total of 11 FANUC robot cells are used to enable long hours of continuous unattended operation. A FANUC robot cell consists of multiple machining centers and a setup station whereby machined parts are attached to and detached from tools by an intelligent robot. The intelligent robot is capable of handling machined parts of various sizes by using a servo hand, and attaching machined parts precisely by measuring the position of a part with a vision sensor. FANUC robot cells enable unattended operation not only during weekday nights but on weekends and holidays as well, thus achieving high machine operability. Parts machined by a FANUC robot cell are carried to the deburring cell of an intelligent robot, where deburring is performed by the intelligent robot, instead of by a human operator. The FANUC robot cell automatically recognizes the part (edge) to be deburred by means of a vision sensor and generates the robot path. It also controls the pressing force of the tool so that the force is constant, by using a force sensor. These functions have made it possible to adapt to changes in burrs of machined parts, resulting in better quality. Every machined part that has been deburred and cleared of turnings is carried to a 3D measuring robot cell, where an intelligent robot attaches it to 3D measuring equipment for automatic size measurement. Intelligent robots are deployed in the processes of machining, deburring, and inspection, in order to automate the machining factory. Robot cell Deburring cell of an intelligent robot The Third Milling Factory uses FactoryTalk View, software from Rockwell Automation, to monitor all the processes in the factory. The status of the machine of each robot cell, the progress of machining, and the robot operation status are monitored from a factory operation monitor in the factory office. Monitoring of the factory operation status using FactoryTalk View Monitoring of the machine status and the progress of machining 8

9 Exhibition Information Tokyo International Packaging Exhibition (TOKYO PACK 2014) Period: October 7 (Tue) - 10 (Fri) Venue: Tokyo Big Sight Exhibits: Sorting system for supply conveyors Gift packaging system Food packaging system Container sorting system Cart-conveyor container transfer system International Plastic Fair 2014 (IPF 2014) Period: October 28 (Tue) - November 1 (Sat) Venue: Makuhari Messe Exhibits: Stable molding of precision lenses for smartphones Stable molding of ultra-thin light guide panels High-speed cycle molding of food containers Stable molding of medical containers Stable molding of precision connectors and testing/ sorting systems Space-saving all-in-one molding system with a built-in compact robot Bimaterial molding system connecting two molding machines via a robot Bimaterial molding system equipped with a second injector Film insert molding system for automotive interior parts Centralized four-site management system using the FANUC ROBOSHOT-LINK+ Four Seasons of FANUC Here are photos of FANUC's forest taken during the short fall season before the oncoming long winter. Miyamauzura (photo taken in front of the Robot Factory on September 1) The blurry white flowers look like a ghost lurking in the dark. Tamagodake mushrooms (photo taken in front of the Robot Factory on September 1) This year again, the bright red mushrooms appear after rain to add color to the forest. Hanaiguchi mushrooms (photo taken in front of the Nature Hall on September 26) Though demure compared to the Tamagodake mushrooms, these mushrooms are a fixture of fall in FANUC's forest. Yamaguri chestnuts (photo taken in front of the Nature Hall on October 8) Small as they may be, the Yamaguri chestnuts taste very sweet. They have grown in abundance this year, as always. Naginatakoju (photo taken in front of the Nature Hall on October 8) The plant has only one side of its spike covered with flowers and gives off a unique scent. Maple trees and the Tsuriike Pond (photo taken at the Tsuriike Pond on October 24) The fall season at FANUC is characterized by the bright contrast of the blue sky, colored leaves, and the factory buildings painted in yellow. 9

10 Visit to a User FANUC FA Products Hitachi Ltd. Power Systems Company, Hitachi Works We visited Hitachi Works, which plays a central part in the electronic power systems and power distribution business of Hitachi Ltd., one of the world's leading electronics companies. Hitachi Works has five factory complexes in Hitachi City (occupying a total of 1,084,000 square meters of land). At its Rinkai Factory, a towering machine tool machines metal containers (metal casks used to transport used fuels). Hitachi Works develops sophisticated production facilities like this internally. What kind of product are you currently focusing efforts on? Chief Engineer Hirai: We produce products like electric power distribution equipment and power plants in the field of social infrastructure. For consumer use and industrial use, we manufacture medical devices like proton beam therapy systems and MRI machines, nuclear fusion devices and particle accelerators, and industrial motors. We are focused on new energy sources in particular, such as solar light and wind power. For wind power generation, we use the down-wind method, which is suitable for Japan, a mountainous country surrounded by sea that is often hit by strong winds and storms. We have the top share of the Japanese market for 2-MW wind power generation systems. It is expected that there will be a growing need for offshore wind power generation in the future that has fewer limitations in terms of location, landscape, noise, etc. At Hitachi, we are currently developing a 5-MW wind power generation system. The system received this year's Good Design Award. Such a system will be installed on the ocean where conditions are unstable, not on land. So we are going to repeat tests using a demonstrator and then proceed to further development. The proton beam therapy system precisely locates the exact position of a cancerous tumor in a living organ and concentrates the proton beam energy to that part to treat cancer. Compared to conventional radiotherapy and surgery, this system does not cause much physical damage to the patient. This eliminates the need for the patient to be hospitalized, allowing him or her to continue therapy while maintaining the quality of life (QOL). The system is used in many medical institutions around the world. You manufacture cutting-edge facilities in many different areas. Chief Engineer Hirai: At Hitachi, we internally develop From right to left: Senior Engineer Chiba (in charge of CNC hardware and robots); Chief Engineer Hirai, Assistant Section Manager Ishiguro and Senior Engineer Chiba (in charge of CNC software) special production facilities and systems as well. For example, if an expensive machined part like a rotor shaft is defective, it will result not only in higher cost but also in the deadline being missed. We have developed a cutting error prevention system that stops the machine if any possibility of a cutting error is found during the machining process. One of the Hitachi Group's advantages is that we have divisions dedicated to the development of materials and new tools. This makes it possible for us to internally design tools suitable for cutting new materials developed by the laboratory, and tool paths best suited to use those tools. Maintenance of CNC units is also performed internally. What do you think of FANUC CNCs? Chief Engineer Hirai: Currently, we have over 100 machine tools, and more than half of them are equipped with a FANUC CNC. The primary reason that we use FANUC CNCs is their high reliability. Because of the nature of our products, machining errors are not tolerated. We have to use the machine tools in an environment where the temperature can be as high as 40 degrees in summer, but FANUC CNCs work just fine. Assistant Section Manager Ishiguro: We sometimes transfer the machine tools that we use in Japan to factories in foreign countries like Indonesia. I think that FANUC CNCs are awesome because they almost never fail. Chief Engineer Hirai: As the policy of Hitachi Works, maintenance of CNCs is performed internally. By focusing on FANUC CNCs, we are consolidating know-how and knowledge. When we develop or introduce a new kind of machine or function or when we replace foreign-made CNCs, we get a lot Yamate Factory we visited for this article Internally developed tool for cutting hard-to-cut materials 10

11 FANUC CNC mounted on a huge turning center Machining of a power generator shaft of support from FANUC. We have a maintenance contract with them, and they are doing a good job in terms of service as well. Assistant Section Manager Ishiguro: The maintenance contract is well devised. Their fast, sincere service is really helpful. The service is available 24/7, and there have been cases that we had the maintenance personnel come over at night. Also, FANUC's manuals provide detailed information, which makes internal maintenance easy. Do you have any requests to FANUC? Senior Engineer Chiba (in charge of CNC hardware and robots): I have been in charge of FANUC CNCs since the FS15 Series. These CNCs are highly reliable, and we can use them with an easy mind. So I would like them to continue to produce high quality CNCs as they have in the past. Of course, we would like price cuts, too (laughter). Senior Engineer Chiba (in charge of CNC software): I assist members of the factories in CNC programming, so I read FANUC's voluminous yellow manuals all the time. I think it would be great if we could view the manuals on the Web. Chief Engineer Hirai: I'm interested in automation and robotization. We manufacture a wide variety of large products in small quantities, and it is impractical in terms of space efficiency for robots to work inside safety fences. I think it would be nice if we had a collaborative work environment where robots do their jobs in one area and human workers do theirs in another area in a well concerted manner, including safety checks. I expect that the Collaborative Robot that FANUC announced the other day will meet this request. (Interviewed by Kyoko Takatsugi, Manager of the Public Relations and Advertisement Department) Offshore wind power generation system (Wind Power Kamisu 2nd Offshore Wind Farm of Wind Power Co., Ltd.) Proton beam therapy system (PROBEAT-RT delivered to Hokkaido University) Hitachi Works, Power Systems Company, Hitachi Ltd. ( Address: 3-1-1, Saiwai-cho, Hitachi-shi, Ibaraki Prefecture, Japan Phone: Number of employees: Approx. 3,700 General Manager: Kenji Urase Headquarters: Address: 1-6-6, Marunouchi, Chiyoda-ku, Tokyo, Japan Phone: President and COO: Toshiaki Higashibara Sales: 2,070,147 million yen Founded: February 1,

12 Collaborative Robot that works safely with human workers FANUC News 2014-Ⅲ Oshino-mura, Minamitsuru-gun, Yamanashi Prefecture, Japan Phone: Fax: Person in charge of publishing: Kyoko Takatsugi, Manager of the Public Relations and Advertisement Department FANUC CORPORATION February Printed in Japan