Efficiency Archives - Used Robots

YASKAWA BOOSTS AFRIT’S PRODUCTIVITY WITH ADVANCED ROBOT WELDING

Afrit, the leading trailer manufacturer in South Africa, has achieved a significant breakthrough in its productivity by implementing innovative technologies in its manufacturing processes. In 2019, the company began executing an ambitious five-year plan with the aim of optimizing the quality of its products and improving workflow at its plant. The pillars of this plan are based on reducing production costs, improving performance, and aligning with the advances of Industry 4.0, with a clear focus on digitalization and automation.

Investment in Robotic Welding Technology

One of Afrit’s major investments was the installation of an advanced robotic welding cell from Yaskawa, equipped with Motoman MH2010 robots. These robots have a large working area, thanks to their Z and Y axes, which reach 3 and 3.5 meters, respectively. The total length of the system is 24 meters, allowing it to adapt to the production of large components, such as trailer containers. The support pillars, more than three meters high, and the ability of the robots to move around the containers ensure precise and efficient welding.

The welding system includes manipulators at the ends that allow the containers to be rotated during the process, ensuring that each part is worked on evenly. Additionally, the robots are equipped with cameras that offer real-time control and monitoring, allowing supervision of the work quality and making adjustments as needed.

Increase in Productivity and Cost Reduction

Thanks to the implementation of this robotic cell, Afrit has managed to double its productivity, increasing production from 8 containers per day to between 16 and 20. This increase has resulted in significant cost reductions and an improvement in the quality of the final products. Furthermore, the incorporation of Delfoi Apexiz software has been crucial in optimizing processes, as it has reduced manual programming time by 80% and programming time by 60%. This has allowed Afrit to accelerate production times and minimize errors associated with manual tasks.

New Facilities and Infrastructure Improvements

As part of its expansion plan, Afrit has also invested in the construction of a new 12,500 m² plant to house the new equipment and improve material flow in production. This expansion has been key to increasing manufacturing capacity and facilitating the integration of new technologies. The plant now features advanced equipment, such as the NitraLife nitrogen gas filtration system, which ensures the quality of the gas used in cutting machines, and the new BLM LT 8.10 3D tubular tube, which optimizes production processes.

Innovation in Component Design

In product design, Afrit has adopted a more flexible approach, with the ability to produce up to 2,293 different variations of tubular components. The company has also invested in 3D design software, such as PTC’s CREO 3D, used by its team of 23 engineers in the R&D department. This technology allows for greater customization of products and contributes to the continuous improvement of efficiency in the design phase.

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DIGITISED ROBOTIC CELLS: THE FUTURE OF INDUSTRY 4.0 IN ACTION

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Industry 4.0 is redefining the boundaries of modern manufacturing, and one of its fundamental pillars is advanced robotics. With the introduction of digitized robotic cells, manufacturers are transforming their processes to achieve greater flexibility, efficiency, and productivity. Iconic brands like KUKA, FANUC, ABB, Yaskawa Motoman, and Kawasaki are leading this transformation by integrating advanced solutions in digitalization, artificial intelligence (AI), the Internet of Things (IoT), and digital twins. But how is this new era of robotics impacting factories and the industry in general?

The Convergence of Robotics and Industry 4.0
Digitalization 4.0 has opened up a range of opportunities for robotic cells. These cells, which previously operated in isolation, are now connected to a network of intelligent systems that allow for more efficient management of operations. Through cloud-based platforms and IoT, robots can exchange data in real-time, access remote diagnostics, and perform predictive maintenance, reducing downtime and optimizing production processes.

The adoption of artificial intelligence and the analysis of large volumes of data allow robots to not only be smarter but also more autonomous, capable of adapting to changing conditions and performing complex tasks without human intervention.

KUKA: Innovation in Connectivity and Digital Simulation
KUKA, one of the giants in industrial robotics, has implemented cutting-edge technologies such as the KUKA Sunrise.OS system and the KUKA Connect platform to facilitate the programming, control, and monitoring of its robots. The former, an advanced operating system, allows for intuitive and flexible programming, while the latter, cloud-based, connects robots to a global network for real-time data access. This connectivity facilitates predictive maintenance and improves factory resource management, optimizing production.

Additionally, the integration of digital twins allows KUKA to simulate and optimize production processes before physically implementing them, reducing risks and improving operational efficiency.

FANUC: Pioneers in IoT and Predictive Maintenance
FANUC, another key player in industrial robotics, has adopted the concepts of FANUC FIELD and ROBOTICS+, IoT-based platforms that offer advanced data analysis and predictive maintenance capabilities. These solutions allow operators to manage and monitor robots from anywhere in the world, ensuring performance remains at optimal levels.

The Arc Mate 100iD robots, primarily used for welding applications, are a clear example of how FANUC has integrated Digitalization 4.0 into its robotic cells. Equipped with advanced sensors, these robots can make real-time adjustments to their welding paths, improving the precision and quality of the final product.

ABB: Connectivity and Simulation for Production Optimization
Swiss giant ABB has launched ABB Ability, an industrial IoT platform that connects its robots, controllers, and other machinery to a digitized network for real-time data monitoring. This platform not only facilitates data collection but also allows for robot diagnostics and failure prediction before they occur.

The IRB 6700, one of ABB’s most robust robots, exemplifies how the brand is incorporating advanced digital technologies into its robotic cells. Through ABB Ability, users can access real-time operational data, improving process efficiency and ensuring consistent product quality.

Yaskawa Motoman: Flexibility and Collaboration in Production
Yaskawa Motoman has implemented collaborative robotics solutions with the MOTOMAN HC10, a robot designed to work safely and efficiently alongside humans. Equipped with advanced sensors, this robot can adapt to its work environment, making it an ideal option for assembly, handling, and packaging tasks. Additionally, through its Yaskawa Fleet Manager platform, users can manage multiple robots in the plant, optimizing resource use and increasing productivity.

Moreover, the integration of predictive maintenance through IoT platforms has allowed Yaskawa Motoman to reduce unexpected downtime, improving operational profitability.

Kawasaki Robotics: Collaborative Robotics and Digital Twins
Kawasaki Robotics is also adopting advanced Industry 4.0 technologies, standing out for its implementation of IoT and digital twins. The RS007N, a compact robot, is a clear example of how the brand is digitizing its processes. Equipped with intelligent sensors and its own IoT platform, it allows for real-time data collection to optimize assembly and material handling processes.

Like other brands, Kawasaki uses digital twins to simulate the behavior of its robots in virtual environments before making changes in the real world, allowing for adjustments without interrupting production.

The Future of Robotics: More Connected, Smarter, More Efficient
The future of robotic cells is promising. The integration of advanced technologies such as IoT, artificial intelligence, digital simulation, and digital twins is making robots increasingly autonomous, flexible, and efficient. Brands like KUKA, FANUC, ABB, Yaskawa Motoman, and Kawasaki are leading this change, offering advanced robotics solutions that enable companies to improve their competitiveness and reduce costs.

Digitalization 4.0 is not only changing how robots interact with humans and machines but is also transforming the global manufacturing landscape. As factories become smarter and more connected environments, the benefits of digitized robotics become increasingly evident, enabling faster, more flexible, and sustainable production.

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URC AND THE KUKA EDUCATIONAL ROBOTICS PACKAGE: INNOVATION IN INDUSTRIAL TRAINING

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In the field of technology and industrial automation, education and training are essential to prepare the next generation of engineers and technicians. URC, a leading company in automation solutions, has developed the KUKA Educational Robotics Package, a comprehensive tool designed to teach students and professionals the skills necessary to operate and program industrial robots.

Technical Specifications of the KUKA Educational Robotics Package
The KUKA Educational Robotics Package from URC includes an educational robotic cell that can contain different models and brands of robots, both new and refurbished. Some of the available models include:
• FANUC LR-Mate 200iC/5L (refurbished)

• KUKA Agilus KR6R700 sixx (new)

• ABB IRB120 M2004 (refurbished)

The package also includes advanced controllers such as the Fanuc R-30iA Mate with iPendant, the KUKA KRC4 compact with SmartPad, and the ABB IRC5 with pendant.

Competitive Advantages
One of the main advantages of the KUKA Educational Robotics Package is its flexibility and adaptability. The educational cell is designed to be highly modular, allowing the integration of different robots and tools according to the specific needs of each client. This includes options such as spindles, gripping clamps, vacuum grippers, and welding torches.

Additionally, URC has established a cooperation with Sprutcam to provide offline programming software with an educational license, facilitating the learning and practice of robotic programming in a safe and controlled environment.

Efficiency Improvement
The use of the KUKA Educational Robotics Package in educational and training environments offers multiple benefits in terms of efficiency and productivity. By providing students and professionals with practical and direct experience with industrial robots, the learning process is accelerated, and the understanding of robotic applications in modern industry is improved.

The educational cell allows for a variety of applications, including palletizing, loading and unloading parts, machining, part handling, polishing, measuring, part assembly, adhesive bonding, and plasma cutting. This versatility ensures that users can acquire a wide range of skills applicable to different industrial sectors.

The KUKA Educational Robotics Package from URC represents a strategic investment in the training and education of the next generation of professionals in industrial automation. With its focus on flexibility, customization, and efficiency, this educational package not only prepares students for future challenges but also contributes to the continuous improvement of productivity and quality in the industry.

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THE FUTURE OF INDUSTRIAL AUTOMATION: FANUC M-900iA/600

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In the competitive world of industrial automation, the Fanuc M-900iA/600 stands out as a robust and versatile solution offered by URC. This industrial robot provides significant advantages for handling large parts, palletizing, and machining, key sectors where efficiency and precision are essential.

Technical Specifications

The Fanuc M-900iA/600 is a 6-axis robot powered by electric servomotors, designed to operate with extreme loads. A look at its technical specifications highlights its exceptional capabilities:
• Payload capacity: 600 kg, with an option to extend up to 700 kg.

• Reach: A horizontal arm reach of 2832 mm facilitates the precise handling of large parts.

• Repeatability: With a repeatability of 0.3 mm, it ensures high precision in all operations.

• Mounting: Its design allows for floor mounting, easily adapting to different plant configurations.

Competitive Advantages

The robustness and adaptability of the M-900iA/600 make it a preferred choice for optimizing industrial processes:
• High Payload Capacity: Ideal for heavy load handling operations, crucial in sectors dealing with bulky materials.

• Reliability and Efficiency: FANUC’s servo systems ensure high uptime and productivity, minimizing downtime due to technical failures.

• Durable Mechanical Design: Its sturdy structure drastically reduces downtime, increasing mean time between failures and reducing the need for spare parts.

• Environmental Protection: With an IP67-rated wrist design, it is resistant to harsh environments. An optional package for severe dust and liquid protection is also available.

• Minimal Interference: Slim arms and wrists allow operation in confined spaces without interference, maximizing workspace utilization.

• Visual Guidance: Capable of integrating with vision systems for camera-guided and error-proof applications.

Industry Impact

Sectors dedicated to handling large parts, palletizing, and machining greatly benefit from the M-900iA/600 due to its ability to handle heavy and repetitive tasks with high reliability. These robots not only improve operational efficiency but also ensure a return on investment with increased production and reduced downtime.

In summary, the Fanuc M-900iA/600 represents a significant advancement in industrial robotic automation, promising companies the flexibility and durability needed to face the challenges of an ever-evolving market. With the introduction of such advanced technologies, URC continues to lead the way towards a more automated and efficient future.

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FANUC RAISES THE STANDARD IN ROBOTIC CONTROL WITH THE R-50iA

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FANUC, a global leader in industrial automation, has recently launched the R-50iA, an advanced robot controller that promises to significantly improve the performance and efficiency of robotic operations. This new controller, based on 50 years of automation experience, offers a range of enhancements and new features designed to maximize robot performance and ease of use.

Control Performance Improvements
The R-50iA features improved control performance that doubles the precision of signal output and sensor tracking in the robot’s movement path. This is especially beneficial for demanding robotic applications, such as adhesive application and other tasks requiring exceptional control.

Enhanced Integrated Vision
One of the standout features of the R-50iA is its enhanced integrated vision. The controller includes a five-megapixel camera, four times the resolution of the previous version, significantly increasing the robot’s field of vision. Additionally, the unified Ethernet network connection allows the new waterproof camera with LED lighting to be controlled using just one Ethernet cable.

Energy Efficiency
The R-50iA also stands out for its energy efficiency. The new six-channel amplifier is designed to consume less energy, and the low-power fans ensure efficient cooling without consuming too much energy. Furthermore, the controller’s eco mode allows for further reduction in the robot’s energy consumption, contributing to energy conservation and sustainability.

Cybersecurity
The R-50iA is the world’s first robot controller to obtain third-party cybersecurity certification, IEC62443-4-1 and 4-2. This controller provides multiple layers of defense to secure data exchange, whether remote access (SSH), file transfers (SFTP), or web communication (HTTPS). It also includes password-based user authentication, simplifying user group management in the field and preventing unauthorized access.

Remote Maintenance Functions
Another innovative feature of the R-50iA is its remote maintenance capability. Experienced FANUC service representatives can provide advice on robot configurations, alarm conditions, and programs, protecting important customer information through secure and confidential communication methods.

The launch of FANUC’s R-50iA represents a significant advancement in robot controller technology, offering powerful performance, energy efficiency, and enhanced cybersecurity. This controller not only improves the precision and efficiency of robotic operations but also aligns with eco-friendly practices, contributing to a more sustainable future.

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