Mr. Brandstetter, what added value do machine manufacturers expect from integrating robots into their machines?

Sebastian Brandstetter: I basically see three advantages: Firstly, robots make machines more flexible; secondly, some processes can be implemented more easily with a robot; thirdly, robots can relieve people of dangerous, strenuous and monotonous work.

Do you have an example of how a robot can be integrated into a system?

Brandstetter: Let's take a look at a filling line for shampoo bottles of different shapes and sizes. The empty bottles are fed in randomly on a conveyor belt. A pick-and-place robot picks a bottle from the belt, whereby the robot receives the movement data from a vision system, and places the bottle on the shuttle of a transport system such as our Acopostrak.

Can't a machine like this also be implemented using a conventional robot system with external control?

Brandstetter: It's not that simple. For a pick-and-place robot to be able to pick up individual bottles, its controller needs real-time information about where the bottle is currently located and how it is aligned. Information on the dimensions is also required in order to clamp the bottles securely between the shuttles. All of these processes must be synchronized within a few microseconds.

You mentioned that robots make machines more flexible. Please explain this in more detail.

Brandstetter: If we look at classic production machines, they are specifically designed for one product or even one product type. In some cases, complex mechanical devices are installed, for example to transport a product from one machine level to the next. If the product changes in terms of size, weight or shape, these devices have to be adapted, replaced or even redesigned. A robot doesn't care, it adapts its path planning to the new conditions if necessary and the machine can continue production.

That sounds as if robots would make every machine more productive.

Brandstetter: I wouldn't go quite that far. But I think that robots actually pay for themselves in far more cases than is generally assumed. This also applies when it comes to operator safety.

In what way?

Brandstetter: Take, for example, machines that move very quickly, such as the bottling line mentioned above. Defective or fallen bottles have to be ejected from the process. If this is done by a human, the speed of the system must be reduced to a safe level as soon as someone opens the safety door. However, if a robot removes the bottle in question, the machine can continue to run at full productivity.

But don't integrated robots make machines bigger?

Brandstetter: On the contrary, integrated robots reduce the footprint of a machine. Robots can carry out complex manipulations that previously required complex - and therefore large - mechanical constructions. In addition, our integrated solution eliminates the need for a separate robot control cabinet and the robots can also be mounted upside down or sideways. And if machine manufacturers combine robots with intelligent track systems, they can optimize their machines even further.

How is that possible?

Brandstetter: The shuttles of the track systems can be controlled individually and, as just explained, synchronized with the robot movements with microsecond precision. Processing can take place during the movement and the process can be adapted to other product properties at any time without hardware changes. This increases throughput and reduces the required floor space.

What does this mean for the machine manufacturer?

Brandstetter: They can offer their customers a completely new type of machine, a machine that automatically adapts to the product to be manufactured - even if this specific product was not even known when the machine was developed. In this way, manufacturing companies can fulfill one of the most urgent wishes of consumers: Customized products at the price of mass-produced products.

Delta robots integrated

B&R has integrated the Codian robots D2, D4 and D5 into its automation system. This means that high-precision pick-and-place applications can now be implemented within a short space of time. Adaptive and flexible manufacturing and logistics concepts and small quantities down to batch size 1 require a rapid response to changing requirements. It therefore makes sense to expand automation to include robots. B&R has integrated several Codian delta robot series into its automation system to minimize the effort for the machine manufacturer. The customer thus has one supplier for the control and development environment and robotics. Since a controller can control both the machine and the robot, there is often no need for a robot control cabinet. This reduces the footprint of the system. Predefined function blocks make it easier to program the motion sequences. The performance parameters of the robots are provided in accordance with ISO 9283, which makes project planning much easier and eliminates the need for in-house performance tests. In addition, the unit consisting of robot, controller, operating device and software is already declared as "Partly Completed Machinery" in accordance with the Machinery Directive. During operation, the end user benefits from the precise synchronization of the mechanical axes and robot movements. This guarantees short cycle times and therefore faster production and shorter logistics processes. In addition, robotics and automation have the same user interface, making training easier. Load capacity of up to 125 kg Codian robots make it possible to sort, assemble or arrange products at conveyor belt speeds of up to 60 m/min. The spectrum ranges from very small kinematics with a payload of up to 1.5 kg and a minimum working range of 500 mm to 2100 mm, which are also suitable for cramped installation conditions, to larger models with a payload of up to 35 kg or even 125 kg. This allows pick-and-place tasks to be carried out even with heavy products. Special hygienic versions are available for primary packaging in the food and luxury food industry.

Part of the modular software system

With a ready-made software solution from B&R, machine builders can now implement pick-and-place applications without a major investment risk. Mapp Pick&Place makes machines faster, more flexible and more efficient. The pick-and-place process solution is based on the Mapp Technology modular software system and is therefore automatically connected to all other Mapp software components. Coordination with other axes, track systems, the B&R vision system or the web-based Mapp View visualization can therefore be set up with just a few clicks. Much of the manual programming work is eliminated and development time is shortened. With the B&R solution, the application developer does not need in-depth knowledge of robotics; all he has to do is select preconfigured functions and link them together. A functioning robotics application can be created in just a few minutes. The risk of expensive misdevelopment is minimized. With the Mapp Robotics component for pick-and-place applications, any number of Delta robots can be used. The number of conveyor belts for infeed and outfeed can also be configured as required. In addition, the software automatically optimizes the process to achieve a maximum pick rate.