TRADE FAIR Rapid development in the packaging market

REPORTJungheinrich AG: Logistics made easy with MOTOMAN robots

REPORTNedCar: 165 MOTOMAN robots for highly flexible production

REPORTNibe AB: Made-to-order production with shorter lead times

MOTOMANNEWS Customer magazine of YASKAWA Europe GmbH, Robotics Division

ISSUE 20

FOREWORD • CONTENTS2

Contents

Foreword

New organisation and products strengthen YASKAWA in Europe 2

Latest News

Groundbreaking for multi-million euro investment in Allershausen, near Munich 3

Girls’ Day 4

The “TheoPrax model” in Munich 4

YASKAWA receives official recognition as a provider of vocational training 5

Complete solutions from a single source 5

Focus

Next-generation bonding 6/7

Report

Jungheinrich AG, D-Landsberg/Halle: Logistics made easy with MOTOMAN robots 8/9

HDG Bavaria GmbH, D-Massing: Investment in even greater quality 10/11

NedCar, NL-Born: 165 MOTOMAN robots for highly flexible production 12/13

Nibe AB, Sweden: Made-to-order production with shorter lead times 14

SYMACON GmbH, D-Barleben: Mobile Robot Platform RPm for efficient flexibility 15

Innovation

Delta robot complements the MOTOMAN product range from YASKAWA 16

State-of-the-art series palletising robots 17

Plug & Play robotic welding system “MotoWeld-SR350” 18

Trade Fair

“MEDTEC Europe”, D-Stuttgart: Automation on the advance in medical technology 19

“Blechexpo/Schweisstec”, D-Stuttgart: Fully synchronised for greater efficiency in the welding process 19

“interpack”, D-Düsseldorf: Trend topic: Cost efficiency and process efficiency 20/21

“interpack”, D-Düsseldorf: “Rapid development in the packaging market” 22

Event

Focus on the aerospace sector 23

Forthcoming trade fairs

Forthcoming trade fairs in 2011 and 2012 23

New organisation and products strengthen YASKAWA in Europe

Dear customers and partners, Dear colleagues,

Since last year’s merger of Motoman and Yaskawa Electric to form the new YASKAWA EUROPE GmbH (YEU), we can look back on eventful and interesting times in the Robotics Division.

The past year was characterised by a tempestuous economic recovery in Europe. Driven by the automotive industry, the demand for robots and automation systems has risen sharply. Real demand and new orders have vastly exceeded even our optimistic planning targets.

As pleasing as this situation may be, following on from the major economic crisis, which was triggered by the collapse of Lehman Brothers, we are facing enormous new chal- lenges. The main task is to master the explosive influx of new orders, in terms of personnel and logistics, and maintain acceptable delivery times for our systems acceptable.

Thanks to our logistics and warehousing policies, we are in a position to meet the huge increase in demand for standard robots and have been able to avoid the supply shortfalls that many expected and feared in the wake of this spring’s earthquake in Japan.

With reference to the fusion with the drives division of YASKAWA, now the Drives & Motion Division, we have adapted structures in order to activate synergies between the different product lines for the benefit of our customers. We have already synchronised our sales activities for robot and drive components, enabling us to offer a broader product range and more comprehensive solutions competence.

In this context, the processes in the Robotics Division have also been adapted to the new challenges so that we are now in a good position to exploit our potential – both for you, our customers and partners, and also for our workforce – and pursue a long-term growth policy.

The market launch of our new MOTOMAN MPP3 delta robot complements our range in the field of picking-packing-palletising applications. Indeed, we can confidently claim to offer the most comprehensive, and the most high-performance range of products for the packaging, food and beverage industries.

With our newly completed portfolio, we will now be focusing our attention on this area and providing a major boost to the use of robotic technology in the field of “PPP”. At the same time, we shall also be continuing development work in the welding sector. Our customers can rely on us as an experienced supplier of robots, cells and complete systems.

The groundbreaking ceremony for the construction of our new European headquarters in Allershausen, held on 6 September and attended by prominent guests from the world of politics, as well as numerous representatives of the press, clearly demonstrated our stated aim of working for further growth in Europe and received widespread public support. This investment is a clear signal to the markets, to you, our customers and partners, but in particular also to our workforce:

YASKAWA is adopting a more visible presence and is enhancing not only its product competence, but also its service competence, so that we can offer our customers even greater support. To this end, we will also continue to exploit the synergies with the Drives & Motion Division still further.

I look forward to an interesting and challenging future as we continue to work together with you.

Yours Manfred SternPresident & COOYASKAWA Europe GmbH

Imprint

MOTOMANNews Issue 20 (2011)

Editorial Team:Marion Reisertrobotics@yaskawa.eu.com www.yaskawa.eu.com

Design/Layout:Matthias Grießel andAngela Freiberger, Munich

Production and print:Druckerei Vogl, Munichwww.druckerei-vogl.de

Authors: Cecilia Benze, Constantin Bader, Tilo Dobmeier, Jürgen Goroncy, Paul Hafkemeijer, Ralf Högel, Hans-Peter Krug, Eddie Mennen, Oliver Neutert, Ralf Raimann, Marion Reisert, Torben Schäfer, Ulrike Schulz, Renate Singer, Alexander Steiger, Stephan Weitkamp

LATEST NEWS 3

Bavarian Minister for Economic Affairs Dr. Martin Zeil called it a “Joyous occasion for Bavaria and Japan” and broke the ground together with YASKAWA’s Euro-pean directors Koichi Takamiya (Board of Directors, Regional Head Europe, YASKAWA Electric Corporation, Japan) and Manfred Stern (President & COO, YASKAWA Eu-rope GmbH). They were ably assisted by a twin-arm MOTOMAN SDA 10 robot. Other guests of honour at the ceremony were the mayor of Allershausen, Rupert Popp, the Japanese General Consul, Akira Mizutani, and deputy district administrator of Freising, Anita Meinelt. The building company responsible for the project, Takenaka, was represented by Tetsuya Sekiya (President of Takenaka Europe GmbH) and Shiro Osada (Execu- tive Managing Officer, TAKENAKA Corpor- ation, Japan).

On course for growth YASKAWA is investing around 12.5 million euro in the new, representative headquarter. This is also a sign of the high goals that the world’s market leader has set itself for the European market: “We aim to double the number of MOTOMAN robots installed annually in Europe to over 6,000 by 2015,” explained Manfred Stern, President and COO of YASKAWA Europe GmbH, on the occasion of the groundbreaking cer- emony.

European head Koichi Takamiya (Board of Directors, Regional Head Europe, YASKAWA Electric Corporation, Japan) describes the strategy thus: “We are positioning ourselves primarily by means of the added value that we offer customers with our robots.” Accordingly, Allershausen, YASKAWA’s base for its European business activities in the field of robotics, will see particular em-phasis on central functions, such as total customer support, research & develop-ment, customer-specific system adapta- tion and logistics. The new building will also accommodate the additional 50 em-ployees that YASKAWA intends to take on for this by the end of 2012. At the same time, these tasks will also become more centralised.

Showcase for Europe In addition to this practical aspect, YASKAWA also sees this new headquarter, which is visible over a large area, as a showcase for its European customers. “The show-room is the highlight of the new building; it will be impressive,” asserts Yasushi Ichiki (General Manager Corporate Plan-ning YASKAWA Europe GmbH). The plot covers some 14,000 square me-ters and is conveniently situated close to the Allershausen exit from the motorway. Some of the buildings at the previous site in the Kammerfeld industrial estate will remain in use.

The outer design of the new building is based on that of the headquarters of the YASKAWA Robotics Division in Japan. The new building is planned to be ready for use in August 2012.

Japanese global corporation YASKAWA reaffirms commitment to bavarian location

Groundbreaking for multi-million-euro investment in Allershausen, near Munich The Japanese corporation YASKAWA, the world’s leading manufacturer of industrial robots and drive technology with annual turnover of over 3 billion euro, is strengthening its European base in Allershausen, near Munich: construction work for the new headquarters officially began on 6 September with a traditional Japanese groundbreaking ceremony.

First cut (from left to right): Shiro Osada

(Executive Managing Officer, Takenaka

Corporation Japan), Akira Mizutani (Japanese

General Consul), Dr. Martin Zeil (Bavarian

Minister for Economic Affairs) and Koichi

Takamiya (Board of Directors, Regional Head

Europe, YASKAWA Electric Corporation, Japan).

Second cut (from left to right): Tetsuya Sekiya

(President, Takenaka Europe GmbH), Rupert

Popp (Mayor of Allershausen), Anita Meinelt

(Deputy district administrator for Freising) and

Manfred Stern (President & COO, YASKAWA

Europe GmbH, in foreground).

Before the actual groundbreaking, Shiro Osada

(Executive Managing Officer, Takenaka Corporation

Japan) scatters rice in accordance with Japanese

tradition. The ceremony was attended by (from left

to right) Bernd P. Bützler (Deputy General Manager,

Takenaka Europe GmbH, in the background) Koichi

Takamiya (Board of Directors, Regional Head Europe,

YASKAWA Electric Corporation, Japan), Dr. Martin

Zeil (Bavarian Minister for Economic Affairs), Rupert

Popp (Mayor of Allershausen), Akira Mizutani

(Japanese General Consul), Anita Meinelt (Deputy

District Administrator for Freising, in foreground) and

Manfred Stern (President & COO, YASKAWA Europe

GmbH, in the foreground).

(From left to right:) Manfred Stern (President &

COO, YASKAWA Europe GmbH), Koichi Takamiya

(Board of Directors, Regional Head Europe,

YASKAWA Electric Corporation, Japan),

MOTOMAN SDA 10 robot, Bavarian Minister for

Economic Affairs Dr. Martin Zeil and Japanese

General Consul Akira Mizutani.

4 LATEST NEWS

The objective of the “TheoPrax model” project in Munich is to develop ideas for project work of a serious nature for se-condary schools and commercial colleges in Munich. TheoPrax is a teaching and learning system that combines theoreti-cal and practical elements in the skills de-velopment and career guidance of young people. For seven months, 45 pupils from three Munich schools worked together on the project “I am reaching for the stars and building the 21st century – even if only for a moment”. Based on an idea by Munich-based performing artist Berkan Karpat, and under the guidance of the De-partment for Employment and Economic Affairs, the pupils set up an artistic instal-

lation depicting the topic of “creation” and combining audiovisual elements and the programming of a MOTOMAN robot.

The resulting work was on show at an exhibition in Munich from 26 to 28 July 2011.

The “TheoPrax model” in Munich Inter-school TheoPrax project on the topic of “creation” with performing artist Berkan Karpat.

Seven pupils from the Helen-Keller-Realschule confidently demonstrated the topic of “creation” with a specially programmed MOTOMAN industrial robot: the Big Bang starts with the bursting of balloons, the element “wind” is created by the loading and unloading of plastic parts, and language is symbolised by the writing of the word “HELLO”.

What is the objective of Girls’ Day? The name is largely self-explanatory. Parti-cularly in technical professions, women are largely under valued.The aim is to make girls aware at an early age that many typical “men’s jobs” can also be attractive and interesting for women. At YASKAWA, this means the professions of engineers and electronics technician for devices and systems. The girls were introduced to both profes- sions, with their widely differing career paths. At the start of Girls’ Day, the girls stated what careers they currently envisaged for the future. About two-thirds of the children already had clear ideas: teacher, zookeeper, vet, architect or writer. A list was then drawn up of the different careers and opportunities to be found at YASKAWA. The spectrum ranges from accountancy, human resources manage-ment, wholesale and international trade and IT specialist to electronics technician for devices and systems and engineer. Many of these jobs are performed by both men and women. In technical func-tions, however, women are in a small minority. This is why the engineering pro-fession was presented first at Girls’ Day. This profession requires university or tech-nical college entrance qualification, which

means that children already need to make certain decisions at an early stage. Engi-neers are trained in a wide range of differ- ent fields: aerospace, mechanical engineer- ing, chemical engineering, communications technology, mechanics, construction engi-neering, mechatronics, biotechnology and environmental technology. These functions are also used in many dif-ferent areas of the companies they work in, such as: development, planning, sales, technical consultancy, application consul-tancy, inspection and assessment, techni-cal writing or customer service. After this introduction to the theory, the girls headed for the laboratory. Here, Karen Reiter described her career and her work as a software engineer at YASKAWA. Some of the girls ran two motors on the test stand and adjusted the speed and torque. On a visit to the EEU workshop, trainee Christopher John reported on his work dur- ing his training as an electronics technician for devices and systems and showed the girls some practical examples of his work. These included a workpiece produced for his intermediate exams. A glance into the warehouse was followed by lunch in the canteen where COO Man-fred Stern addressed the girls with friendly words.

The highlight of Girls’ Day came in the se- cond half: in the showroom, a two-armed robot showed how it can apply a name to a ruler. All the children then received a ruler with their own name on it. In the YASKAWA Academy, training man- ager Torben Schäfer demonstrated robots covering a wide range of different tasks: from robots for screen coating applications and welding robots to robots for vehicle wheel handling operations. The most exciting thing for the girls, of course, was having the opportunity to control a robot by themselves. Once again, it was amazing to see how quickly children pick up the concept of using the teach panel and the robot and how they made “child‘s play” of robot operation. At the end of Girls’ Day, the girls had to write down their intended career once again. It came as no surprise that there was sig- nificantly increased interest in careers with robots. To round off the day, the partici-pants were all given a number of small presents and a group photo was taken. The girls were highly enthusiastic about their visit to YASKAWA and – who knows? – perhaps some of them may one day find themselves working in a technical pro- fession with our company in about 8 to 15 years.

On 14 April 2011, Girls’ Day events were held at YASKAWA Europe in Eschborn for the second time. All available places were already booked after just 2 days. Girls from 10 to 13 years of age from nearby schools took up the offer, together with 2 daughters of colleagues.

LATEST NEWS 5

A uniform, overall technical solution for the entire packaging process may take the following form: an MPP3 delta robot picks up the product in its primary packag-ing – e.g. a packet of sweets – and de-posits it at high speed in a carton or shallow tray. In a second step, a 5-axis MOTOMAN MPK2 robot takes over. With its streamlined gripper and 400 mm long Z axis, it is ideal for loading crates and deeper trays. With a payload capacity of 2 kg, it manages up to 133 cycles per minute. This complex, high-speed process is managed by the MOTOpick process man-agement software. This software controls both the integrated image processing functions and conveyor tracking. Correct positioning of the correct product is thus automatically assured at all times. More-over, MOTOpick provides the system operator with a user-friendly interface that can be used for the quick and straight forward creation of new patterns. The remaining packaging process for the previous pre-grouped components is con-trolled by, for example, an MPK 50, one of many options offered by YASKAWA’s wide-ranging robot portfolio.

It is a four-axis robot with a payload ca-pacity of up to 50 kg and an almost right-angled working envelope that it covers at high velocity, making it ideal for this task. The MOTOMAN MPL series, de-signed for the downstream palletising operations, is also designed with a 4-axis configuration and comprises the widest range of 4-axis robots on the market. The robots of the MPL series are available for payloads from 80 kg to 800 kg and palletising heights of over 3 meters. They are very fast and, thanks to their large workspace and compact design, they can be integrated into system concepts with great flexibility. A comprehensive range

of software solutions completes the total package from YASKAWA. The simulation of complex cells in the planning phase and the programming and control of the palletising system are simple with the wide range of products and services from YASKAWA. Robotic packaging lines such as this offer decisive advantages over conventional linear or gravity packers: they are gentle on products, can be used is a flexibly way and take up little space. Highly developed control technology produced in house and special application software complete the total package for PPP applications from YASKAWA.

Robot-based packaging solutions from YASKAWA

Complete solutions from a single source The robotic automation of packaging tasks increases the flexibility, productivity and reliability of processes, irrespective of the specific branch of industry. With the MOTOMAN range, YASKAWA offers the required elements for packaging lines: from product picking and packing to final preparation of the pallets ready for shipping.

In addition to the range of services al-ready provided, the YASKAWA Academy is now also able to offer employee quali-fication during short-time work. Follow-ing general approval of the company, 15 training initiatives for four controller generations have already been tested and given an official seal of approval. The local employment agency of the appli-

cant is responsible for issuing the vou-chers following an interview. Further information can be found under “Training” on the YASKAWA website (www.yaskawa.eu.com) or obtained di-rectly from the Training Center Eschborn (Tel. +49 (0)6196 777 25 70).

AZWV funding of YASKAWA training courses with training vouchers:

YASKAWA receives offi cial recognition as a provider of vocational training 15 training initiatives for the MRC, XRC and NX100 robot controllers and the latest-generation DX100 have been evaluated and AZWV-approved.

FOCUS

MPP3 MPK2 MPL series

FOCUS6

For decades, robotic welding has been one of the central core competencies of MOTOMAN. Following the merger with its parent company, MOTOMAN now tra-des as YASKAWA Europe. “Those with high levels of welding expertise also have an advantage when it comes to related processes, such as bonding and sealing,” affirms Ralf Raimann, bonding specialist at YASKAWA. “Particularly with regard to path following performance, the demands on the robot are very similar. Welding processes are often combined with, or replaced by, adhesive bonding processes. We are therefore working in familiar territory.”Market analysis forecasts significant growth potential in the areas of bonding and sealing. The number of applications is steadily increasing in a wide range of

industries, from automotive and subsup-plier industries to aerospace and even the defence and pharmaceutical sectors. There is also potential for growth in areas such as white goods, the construction industry, solar power systems and the processing of high-tech materials. It is for applications such as these that the newly developed process, for which a patent ap-plication has been filed, is set to become a state-of-the-art technology.

Pioneering bonding systemYASKAWA is using a pilot system, which is soon to be used in practice, to demon- strate next-generation bonding.“We developed our pilot system in re- sponse to a specific customer enquiry,” explains Raimann. “Its task is the auto- mated joining of workpieces for the con-

struction industry with single-component material. The advantage is that it is not necessary for the workpiece to be manu-factured with great precision as our tech-nology enables the sealing of different gap widths, from two to seven millime- tres, whilst maintaining a consistently high process velocity.”The innovative bonding system devel- oped by YASKAWA consists of three core components: a six-axis MOTOMAN MH50 robot, a highly dynamic dispensing system and the sensor system, which plays a key role in establishing the gap width. Exact in-line measurement of the gap width with a 2D laser sensor is the basis for controlling the complex process.Various parameters – primarily the travel speed of the robot and the dispensing quantity – have to be controlled in real time and coordinated with each other. Control of the process is based on a number of interlinking control loops.With the innovative DX100 robot control-ler, YASKAWA has achieved outstanding process reliability and can process a wide range of medium and high viscosity single- component materials in the system.

Highly dynamic dispensing systemIn the opinion of suppliers, the Modis dispensing system (Modular Dynamic Dispense System) from Hilger & Kern, is the dispensing technology of the future.

YASKAWA intends to revolutionise bonding and sealing applications using a newly developed process

YASKAWA presents pioneering adhesive bonding technologyA highly dynamic joining process ensures that gap variations are automatically compensated for whilst maintaining a constant robot travel speed. The overall system features high-tech robotics components, dispensing technology and sensor systems, and delivers unprecedented performance.

The six-axis MOTOMAN MH50 robot delivers supreme continuous path performance.

FOCUS 7

According to Ralf Raimann, the YASKAWA bonding cell combines innovative dis- pensing technology with the dynamic characteristics and flexibility of MOTO-MAN robots to produce a complete sys-tem with unprecedented performance: “As far as cost effectiveness and produc-tivity are concerned, we are setting new standards in bonding and sealing applica-tions.”Furthermore, the modular nature of the dispensing system allows a wide range of applications to be considered. Process reliability is ensured for materials such as epoxy resins, polyurethanes and MS polymers, as well as polysulphides and silicone. Depending on the size of the dispenser, flow rates of 120, 600 or 1,500 cubic centimetres per minute are pos- sible, with the system running at a capa- city of 1 to 100 percent. The range of possible applications for the YASKAWA systems is thus virtually limitless.Alongside smaller turntable systems, co-vering a distance of 200 x 200 millime- tres, gantry systems with multiple robots covering twenty metres or more are also conceivable.The process is suitable for joining glass, plastics, metal and wood. The 2D laser sensor, which detects the gap width, plays a decisive role here; this is particularly important in the case of transparent materials. “The sensor specialists from

Keyence not only have the right sensor for every application, they also have expert- ise in configuring and setting up the cor-rect parameters of the sensor systems,” says Ralf Raimann from experience.

Real-time process controlYASKAWA uses the DX100 robot control-ler to control the complex bonding pro-cess. The controller processes the flow of information in its operating system.It also enables ultra-short control intervals, measured in milliseconds, upon which the dynamic process relies. With a view to maximising performance, YASKAWA places great importance on the strict se-paration of the robot controller and the dispensing system controller. An inter-face with real-time capabilities from the robot controller to the dispensing system ensures process oriented internal com-munication between the robot and the dispenser.YASKAWA has selected the six-axis MOTOMAN MH50, which meets all the key requirements for bonding and sealing.Expert Ralf Raimann summarises the ad-vantages of the MH50 as follows: “The path-following performance of the MO-TOMAN MH50 is outstanding in its class and it is also fast and reliable. It is highly compact and yet has a reach of over two metres with a payload of 50 kg. Com-bined with the DX100 controller, it is thus

the perfect machine for bonding and sealing.”The pioneering bonding system can be used for the automatic, reliable and cost-effective joining of workpieces with dif- ferent gap widths whilst maintaining a consistent high travel speed of the robot. This creates additional value potential for the user with more flexible bonding or sealing processes and pre-production.The flexibility of the process and the abil- ity to compensate for gap widths of be- tween two and seven millimetres allow considerably greater tolerances in pre-production. This eliminates the need for cost intensive precision manufacturing in a wide range of applications, resulting in enormous potential savings for the user.

The new bonding process can be used to seal different gap widths reliably and efficiently. Photos: Ralf Högel

REPORT8

Jungheinrich AG, one of the world’s largest suppliers of industrial trucks and logistics solutions, has opened a new plant in Landsberg, near Halle (Germany), for the manufac-ture of electric pallet trucks. MOTOMAN welding robots are responsible for the manufacture of frame components. The new plant is an independent “Center of Excellence” and houses all management, development and production functions for electric pallet trucks. Since 2007, Junghein-rich has invested about 30 million euro in the new produc-tion facility which currently has a workforce of 80 people. Pilot series production commenced on 1 July 2009. Since the summer of 2010, all electric pallet truck variants are manufactured in Landsberg, in a production area covering around 17,000 square meters. For the EJE and ERE series, Jungheinrich welds important components with the aid of state-of-the-art robot techno- logy. The load frames, including the forks, are produced by MOTOMAN UP20MN robots; the drive frames are taken care of by EA1900N welding robots. The blue robots are equipped with welding technology from Fronius which is integrated into the systems by an external service pro- vider. The welding cells also feature numerous fixtures and manual welding stations. Control of the systems is based on Siemens PLC tech- nology, but the NX-generation controller was developed entirely by YASKAWA. Furthermore, the welding specialist

wrote the first programs together with Jungheinrich em-ployees. The service technicians have meanwhile devel- oped over 1,000 programs, which are stored on a central server. The last of the required welding programs were im-plemented in the spring of 2010.

Cooperative welding process For production of the load frames and forks, Jungheinrich set up three welding cells, each containing two robots from Allershausen. Jungheinrich designed the welding cell in such a way that welding can be carried out on one side, while a finished part is removed from the other half of the system and the fixtures are reloaded. This layout requires welding robots with a large working area. The UP20MN has a unique reach of 3,106 millimeters and thus ensures efficient util- isation of the workspace and improved productivity. The two robots in each cell are mounted on a shared track, and the 250 kg bulk packs of welding wire also travel on the axis. Job sharing is the name of the game in the cells: one robot welds several individual components together to form the forks, while the other does the same for the load frames. Once the second robot has completed its program, it helps its “colleague” to weld the forks. Jungheinrich does not exploit the available welding per- formance of the robots to the full in order to keep wear and tear to a minimum.

Logistics made easy with MOTOMAN robots YASKAWA Europe GmbH supplies equipment to many OEMs and their suppliers, not only for welding tasks in exhaust gas systems and vehicle chassis; the Allershausen based company also offers custom tailored and competitive solutions for other industry sectors.

REPORT 9

By way of preparation, the operators load the individual components of the load frames and forks into the fixtures and tack weld them together using manual welding power sources. They then scan the code of the parts into the controller so that the welding robot will select the correct welding program. For each product, there is a suitable welding program on the server with a range of different subprograms. Jungheinrich produces a number of different load frame variants and forks ranging in length from 800 to 2,400 millimeters, with varying widths and thicknesses. Once the robots have completed their tasks, an operator unloads the finished workpiece from the fixture and visually inspects the seams.

Lean production with streamlined robot technology Jungheinrich manufactures the drive frames of the electric pallet trucks in two cells, each containing two MOTOMAN EA1900N series welding robots. These standard welding robots feature an integrated coolant and weld current sup-ply. This results in increased service life of the cables, fe-wer interruptions to operation due to damaged cables, and a more streamlined robot contour. The work sequence from the loading of the individual parts to the offloading of the finished drive frame to the material flow is similar to that for the load frames. A slight dif- ference is that the robots each concentrate on their own tasks and do not help one another out. Load and drive frames are made of ordinary mild steel so no special welding technology is required. Both components are subsequently powder coated and then screwed together during final assembly.

Development goal: “Best in Class” Initial planning for the welding cells was carried out in February 2008. In addition to YASKAWA, other competitors also submitted corresponding concepts which were then successively optimised in partnership with Jungheinrich. The

planning phase was completed in September 2008 and YASKAWA was awarded the contract for the project. One reason was that Jungheinrich already appreciated the quality and reliability of MOTOMAN robots from existing applications. MOTOMAN then implemented Jungheinrich’s concept requirements: of particular importance to the industrial truck specialist was weld quality, an optimal material flow including logistics concept, occupational safety and accessibility for the operators. Additional requirements included factors such as ergonomics, ease of cleaning, compact dimensions and adaptation to the Jungheinrich color scheme. The systems were successively installed and programmed in the spring of 2009. Despite the extremely tight time frame, production was able to commence on schedule in July 2009. The quality, design and cleanliness of the welding cells with MOTOMAN robots set new standards for comparable industrial systems.

REPORT10

Before the welding robot can weld parts for boilers and accessories, the individual parts must first be manually tack welded. An HDG employee accurately positions the components in a clamping fixture (welding gauge) and tacks them in several places. In order to keep distances short, this is done at a specially installed workstation immediately next to the welding robot.

Perfect seams – down to the very last corner An operator trained in working with the welding robot then loads the tacked assembly into the positioner – a fixture on the robotic workstation in which the parts are held in place. The positioner is able to support workpieces weighing up to 500 kg and measuring up to 160 x 250 cm. Furthermore, the parts to be welded can be rotated through 360° about their own axis on the positioner, as well as being moved vertically. This enables the welding torch to join the metal parts together, even in positions that are difficult to reach. Particularly when it comes to welding worm drives, this function for flawless quality of the products is indispensable. Since it is also possible for the welding torch to rotate through 360°, the robot also welds uniformly around curves.

HDG uses Tycon 18 gas with the MOTOMAN EA1900. This is currently supplied from a bank of 12 gas cylinders that are stored outside the production shop.

Simple programming Once the HDG employee has clamped the workpiece onto the positioner, he moves to the operator panel and starts the welding operation. The robot only commences its work when there are no people left in the zone safeguarded by the photo-electric barrier. In order for a welding process to be carried out success- fully, the HDG employee must program the welding robot for each individual part. This is done using the so-called “Teach Pendant”. This teach pendant with touch screen has a user-friendly menu interface and is quick and easy to program. As the dress package with the gas supply hose and wire feed runs directly along the robot arm and is thus located in a fixed position, there is no need to take the routing of the hoses into consideration during programming. This saves time.

Welding robots

Investment in even greater HDG quality A robot track, a robot arm, a positioner and a “Teach Pendant” – these are the principal elements of the MOTOMAN EA1900 welding robot that recently joined the production team at HDG Bavaria GmbH. For the manufacturer based in Lower Bavaria, this new industrial robot constitutes an investment in the company’s future. In the following report, you can find out how the new high-tech machine works.

Exact weld seams and strong joints –

these are the work of MOTO-

MAN robots.

REPORT 11

Advantages of the welding robot While the robot is working at one welding station, the second welding station can be prepared. This means that the HDG employee loads another assem-bly onto the second positioner another object that is to be welded. This largely eliminates idle time for the MOTO-MAN EA1900. In addition to this advantage, and the extremely short pro-gramming time, HDG Bavaria GmbH opted for the welding robot for the following reasons:

•Cycletimereduction•Evengreaterweldingquality(e.g.stablearc,optimal

torch position, ability to weld round radius) •Greatercosteffectiveness

In conjunction with the laser cutting system purchased the year before last, which is used for the precision manu-facture of the individual parts, the robot has enabled HDG to optimise its already high quality even further. For the production team that works with the welding robot, the first implication of the new investment was a five day training course at MOTOMAN. The objective of the coming weeks is to become familiar with the robot and to optimise its utilisation.

Installation dia-gram of the new welding robot at HDG.

The welding robot in action.1 The dress package is permanently routed through the robot arm.

2 The robot moves backwards and forwards on the robot track.

1

2

REPORT12

The wide range of different makes and models that have been produced at NedCar illustrates just how flexible this plant is. In order to achieve this degree of flexibility, NedCar makes use of versatile, modern manufacturing technology. When it comes to robotic technology, NedCar turns to MOTOMAN systems from YASKAWA.

Bodyshop 120 MOTOMAN robots are used in the bodyshop. Thanks to the extremely effective programming, it was possible to commence production of the “Mitsubishi Outlander” within two weeks. Four different types of MOTOMAN robot are used in the production of the Outlander. The MOTOMAN ES200N and MOTOMAN ES200RN (as shelf type models) are primarily responsible for handling and spot welding tasks. The robots often switch from one task to another with the aid of automatic tool changers. All spot welding guns are servo controlled for optimal velocity and weld quality. The electrode tips of the spot welding guns are automatically dressed when worn or fouled by the zinc layer on the body panels. The new “Tool Center Point” (TCP) position is then automatically calibrated and corrected.

Vehicle roof Another interesting process is the clinching process used for joining the roof to the vehicle body. First of all, the roof is automatically loaded by one robot; two MOTOMAN robots with clinching guns then carry out all the joints. MOTOMAN SSA2000 and MOTOMAN EA1900N robots

are also used in the production line as welding robots. These execute MIG weld seams and also a number of MIG-brazed seams. The reliable “MotoWeld” arc welding technology is used for this application.

Door, hood and tailgate In the manufacturer of doors, hoods and tailgates, the flexible roll hemming technique is used. Adhesive is applied to the inner and outer parts at the hem seam and the parts are automatically joined together. Finally, a MOTOMAN ES200N with a special roll hemming head bends the edge of the hem. The workpiece is auto-matically rotated by a servo controlled turntable and the positioner is controlled by the robot. This concept is considerably more cost effective than conventional hemming presses or so-called “table-tops” and easier to adapt in the case of component modifica-tions.

Final assembly In most automotive plants, few if any robots are used in final assembly. At NedCar, industrial robots have been used in final assembly since the mid-90s. The number of MOTOMAN robots performing all manner of tasks there has reached 45 in the mean time.

Wheels In the fully automated wheel assembly station, for example, the wheels are brought to the production line on a con- veyor belt. Using an automatic feed system, a small robot loads the nuts individually into the assembly grippers. The assembly robots then take the wheels and measure the exact position of the thread on the vehicle. Using these measured values, the assembly position is calculated and the wheels are screwed on. The torque is automatically monitored and documented for quality control.

Cockpit In the fully automated cockpit assembly station, the pre-assembled cockpits are transported to the production line on a conveyor belt.While one robot removes the cockpits from the conveyor, another industrial robot measures the exact position of the assembly holes in the vehicle body. Using the measured data, the cockpit is precisely positioned in the vehicle body and another robot screws the component to the body.

165 MOTOMAN robots forhighly flexible production at NedCarThe state-of-the-art NedCar automotive plant in Born (Netherlands) has been making cars for over 40 years. Cars that have been produced there over the decades include the “DAF33”, the “Mitsubishi Spacestar”, the “Mitsubishi Carisma”, the “Smart” and various Volvo models. Models currently rolling off the lines there are the “Mitsubishi Colt” (3-door and 5-door versions) and the “Mitsubishi Outlander”. NedCar is meanwhile a 100 percent subsidiary of the Japanese Mitsubishi group.

REPORT 13

Photo on left: Arc welding and MIG brazing with “MotoWeld-SR350”.

Photo on right: Roll hemming.

Photo on left: Clinching, car roof.

Photo on right: Cockpit assembly with automatic screw fastening.

Photo on left: Assembly and adhesive bonding of windshields.

Photo on right: Seat installation.

Other robotic applications in final assembly are the fully automated bonding and assembly of glass panels (front, rear and side), the placing of seats and the automatic filling of all fluids. All in all, this is a good example of the universal range of potential applications for robotic technology.

Local support from YASKAWA Benelux Training of NedCar employees and after-sales service are carried out directly by YASKAWA Benelux. In this way, NedCar receives optimal local support for modern automotive production tasks.

14 REPORT

The MOTOMAN robot has everything at hand on the accompanying equipment trolley: A complete set of small sheets, multi-funcional grippers and regrip stations.

Short FactsCustomer: Nibe AB, Sweden

Product: Stoves

Industry: Metal fabrication

Application: Press-brake tending

System components: Four identical robot cells with – One MOTOMAN UP50N-35 – Servo powered floor mounted robot – TSL-1000SN robot track – Multi-function grippers – Programming – Robot controller NX100

Results: – Lead time reduced with 90% – One human operator, four robot cells

ChallengeNibe’s 10 robotic arc welding cells (8 from MOTOMAN), each producing their own specific stove type, were being supplied with pressed parts from several manual production lines located far away. Valu- able resources were being spent in trans-port, storage and logistics to keep up production, and Nibe wanted a more cost efficient and productive solution.

SolutionThe whole production operation is initi- ated by the arc welding cells. When they are about to run out of parts for a par- ticular stove type, one (or two) of the four press brake cells automatically starts batch production in order to supply com-ponents. The MOTOMAN press brake cell selects the right program and gripper tools, stocks the accompanying trolley with small sheets and then completes the bending process. Ready-made parts travel in a pallet with RFID information on an automatic conveyor system to the awaiting arc welding cell. Only one human operator is needed to supply materials and keep the four press brake cells in operation.

ResultsProduction on demand with the lead time reduced by 90% means that it is possible to have a vast product range without keeping a large inventory. With all the innovative equipment, such as multi-func-tional grippers, tool changing, pallet racks and pallets that are stocked with many different sheet types, etc., the four press-brake cells are capable of handling up to 80 different sheet sizes. Due to the fact that a majority of the heavy sheet metal parts are now handled by robots, impor-tant benefits also include improved ergo-nomics and fewer injuries.

Nibe AB, Sweden:

Reduced lead time with production on demand

Steps of the press brake cell.

Until now, the following applied to the automated loading and unloading of ma-chines: the higher the degree of automa- tion, the more limited the flexibility of the feeder system. In other words, a fully automated machine tending system can generally only be implemented for a sin- gle machine. Systems allowing variable operation, on the other hand, are less efficient. The new development meets this two fold challenge by combining a universally de-ployable mobile platform with, for example, high performance MOTOMAN robots. In terms of price, the modular series cell thus offers a highly interesting alternative to equivalent dedicated solutions. Another benefit: the customer can take advantage of a tried-and-tested basic system that can nevertheless be customised to individual requirements.

Construction The emphasis of the design was on maxi-mum flexibility: a solid, welded substruc-ture forms the basis of the robot platform. It can be moved around production shops with a fork lift truck at extremely short notice. This means that the machine ten-ding cell can be used in a flexible way at various machine tools. The advantages of this system becomes apparent in the case of varying levels of utilisation, pro-duction change overs and the addition of new tasks. An intelligent referencing solution with stored sequences further enhances the flexibility of the system. Conversion times are thus minimised, and the machine tools are very quickly available once again. The modular nature of the system means that the substructure can be fitted with a wide range of components. The “Mobile Robot Platform RPm” thus unites a com-plex array of technical and technological options in an area of just 1.5 x 2.5 metres. At the heart of the machine tending cell is the robot installed at the center. Compa-red with other solutions – e.g. gantries – robots offer extreme flexibility. The univer- sal platform is suitable for various models in YASKAWA’s MOTOMAN range.

Versatile applications The flexibility of the platform itself is re-flected in the wide range of potential ap-plications for the robot in the production of workpieces: robots such as the MOTO-MAN MH6 or HP20, configured according to user-specific requirements, can support such tasks as grinding, turning, deburring, inspection or measurement. All work steps can be combined with high flexibility without the need for rigid speci-fications. Guides installed directly on the platform allow the robot to be repositioned manu-ally by the operator. This ensures free ac-cess to the workspace of the machine tool. In conjunction with the two safety doors, this functionality also enables convenient tool and clamp changing. The supply of unmachined parts and the handling of finished parts weighing up to 20 kg can be implemented using a wide range of tried-and-tested solutions: the machine tending cell can be configured with all manner of conveyor belts, chain conveyors, baskets, pallets, drawer sys-tems, etc. A NOK/SPC setdown point can also be accommodated. The possibilities of the “Mobile Robot Platform RPm” thus go far beyond those of a dedicated machine tending solution. Increasingly complex production require-ments are supported by a large number of exchangeable process modules. Measuring devices, deburring devices, labeling systems, turnover stations, image processing systems and more can all be implemented in the configuration. An oil thrower, for example, can be used after the grinding of gear wheel teeth to remove oil from the workpiece, thus countering the risk of oil entrainment problems.

Reference application At Zerbster KmB Technologie Gesellschaft für rationelle Fertigung mbH, a sub-supplier to the automotive industry, the robot platform has been running for over a year in three-shift operation. The company manufactures parts, components, mod- ules and systems for motor vehicles and the mechanical engineering industry. Cur-

rent daily production output is about 35,000 parts. The range of products and services of KmB Technologie covers all areas of cutting and non-cutting machin- ing with great manufacturing depth, as well as heat treatment and assembly. The Mobile Robot Platform carries out an ever changing range of different tasks. For Steffen Gädicke, Head of Sales/Pur- chasing at KmB, it was the flexibility of the system that was the decisive factor behind this investment. Equally important was the fact that the costs were lower than those for conven- tional inflexible solutions: “Financial pres-sure in our branch of industry is enormous. We can only stay ahead of our competitors by means of systematic rationalisation,” he says. The decision was taken prior to the economic crisis of the past two years and, in the context of the crisis, has proven to be the correct one.

Summary In a production area of just 1.5 x 2.5 metres the “Mobile Robot Platform RPm” devel- oped by SYMACON for MOTOMAN ro-bots unites a wealth of technical and tech- nological options. It thus ensures maximum flexibility in the production process. The modular configuration can be custom- ised to individual requirements, and the solution also offers an interesting alter- native to other dedicated solutions in terms of price.

REPORT 15

Mobile Robot Platform RPm for efficient flexibility SYMACON GmbH, a specialist supplier of handling and assembly equipment based in Barleben (Germany), has developed a “Mobile Robot Platform RPm” which can be used with MOTOMAN robots from YASKAWA. The modular series cell allows unprecedented cost effectiveness and flexibility for automatic machine tending processes.

User-friendly operator control with a standardised mobile panel.

INNOVATION16

From the picking of bags, cartons and jars in the food industry to the handling of wa-fers in the assembly of solar panels: the range of potential applications for the new MPP3 delta robot is enormous. Its compact dimensions allow space sa-ving installation directly above the con-veyor belts. A standard flange supports a wide range of different grippers. Further-more, with protection classification IP 65, it is easy to clean. Irrespective of the application specific de-sign, the flexible delta robot is characte-rised by one overriding advantage: it com-bines the speed of the delta design with a high payload capacity and a large radius of action.

In the spotlight: maximum availability In this 4-axis robot with a parallel kinema-tic system, the fourth axis, the so-called wrist axis, is significantly stronger than in comparable models. This enables it to move payloads of up to 3 kg at an unpre-cedented speed: 140 cycles per minute with a 3 kg payload and 230 cycles per minute with a 1 kg payload are possible. The conveyors can be operated at a vel- ocity of up to 120 m/min. The working envelope is also very generous. It com- prises a total lift height of 500 mm with a diameter of 1,300 mm in the cylindrical upper section of the working envelope and a diameter of 950 mm in the conical lower section. As with all MOTOMAN brand products, special attention was paid to availability of the machine during development of the new delta robot. One precondition for this are particularly hard wearing parts. Furthermore, these are designed in such a way that they can be quickly and easily exchanged. Given the high mechanical quality, long maintenance intervals and short downtime, the availability of the MOTOMAN robots is approx. 95 percent, which means maximum production, pro-cess reliability and constant quality in a day-to-day operation.

Packaging lines from a single source The performance of the MPP3 is maxi-mised in conjunction with downstream packaging robots. As a new member of the MOTOMAN product family, it can be ideally combined with other products in the range to form complete solutions with seamlessly integrated technology. The result is complete packaging lines from a single source: from picking the product to final preparation of the pallets for shipping. One possible practical application: the delta robot uses its vacuum gripper to pick up the product in its primary packaging – e.g. a packet of sweets – and places it at high speed in a carton or shallow tray. In a second operation, a 5-axis MOTOMAN MPK2 robot takes over. With its stream- lined gripper and 400 mm long Z axis, it is ideal for loading crates and deeper trays.

With a payload capacity of 2 kg, it man- ages 133 cycles per minute. This complex, high-speed process is supervised by the MOTOpick process management soft-ware. This software controls both the in-tegrated image processing functions and the tracking of the conveyors. Correct positioning of the correct product is thus automatically assured at all times. More- over, MOTOpick provides the system operator with a user-friendly interface that can be used for the quick and uncom-plicated integration of new patterns. The remaining packaging process for the correspondingly pre-grouped components calls for robots such as the 4-axis MOTO-MAN MPK50. This robot has a payload capacity of up to 50 kg and a working ra- dius of 360°. The MOTOMAN MPL series, designed for the end of line palletising operations, comprises the widest range of 4-axis robots on the market. It covers payloads from 80 kg to 800 kg and palleti-sing heights of over 3 meters. Here, once again, comprehensive software solutions take care of process control for the entire palletising cell and up to six conveyors. Robotic packaging lines such as this offer distinct advantages over conventional lin- ear or gravity packers: they are flexible in operation but are gentle on the products. Software controlled robots, such as MOTOMAN robots from YASKAWA, can be reprogrammed in a few minutes. Pro-duction can thus be adapted to suit any time at short notice.

Summary With the newly developed MPP3 delta robot, YASKAWA has added to its range of high performance MOTOMAN indus- trial robots the component required for versatile picking applications. This robot combines the speed of the delta design with the high payload capacity, large work- space and process reliability associated with the name MOTOMAN worldwide. The new MPP3 delta robot made its worldwide debut at Interpack in Düssel-dorf from 12 to 18 May.

Delta robot completes the MOTOMAN product range from YASKAWA High payload, large workspace and exceptional speed: the new “MPP3” delta robot for demanding picking tasks completes the MOTOMAN product range from YASKAWA. This new development means that the technological implementation of entire packaging lines is now possible, for the first time, using exclusively products from this manufacturer – thus offering all the characteristic advantages of a leading brand.

INNOVATION 17

YASKAWA presents the innovative, 4-axis MPL palletising robot series for payloads from 80 to 800 kg. These dynamic mo-vers are characterised by extreme accele-ration and enormous axis velocities. At the same time, they have minimal space requirements for installation. The MPL models feature internally routed supply lines (four air hoses and 22 electric cables) all the way to the flange mounting, thus enabling maximum service life of the dress packages. The MOTOMAN MPL100, MPL160, MPL300, MPL500 and MPL800

models are also equipped with a hollow wrist with a diameter of 50 or 60 mm. Even in the case of larger motions of the wrist axis, there are thus no freely routed media packages. Like all new robot models from MOTO-MAN, the MPL series is also controlled using the high performance DX100 cont-roller and can thus be equipped with all commonly-used bus systems, e.g. ASI-S. This bus cable can optionally also be routed internally through the robot as far as the flange mounting.

The undisputed strongman of the series is the MOTOMAN MPL800. This palleti-sing robot has a payload capacity of 800 kg and a wrist axis torque of 500 kgm², thus making it ideally suited to the hand-ling of particularly heavy workpieces. On request, the MPL robots can be supplied with a palletising software package tailored to the customer’s specific requirements, either on a PC or directly on the teach pendant.

State-of-the-art palletising robots The new DX-series MOTOMAN robots have a whole range of new and improved features, including functions for order picking, packaging and palletising applications.

The MOTOMAN MPL800 is ideally suited to the handling of particularly heavy workpieces.

18 INNOVATION

MOTOMAN is the leader in robotic arc welding technology and is extending its scope of supply to offer a complete robotic welding package with the “MotoWeld-SR350” power source for the MOTOMAN MA1900 and MOTOMAN MA1400 robots. This package is a plug & play solution for air cooled MIG/MAG welding, which offers great benefits for cost efficient welding and is user-friendly and easy to install. As a customer, you benefit from our extensive experience in welding applications and the seamless integration of robot, controller, power source, cabling, wire feeder and torch. This welding package is ideal for compact welding cells, first-time robotic welding and for those looking for a simple, but efficient, welding solution.

Key benefits:•Easytooperateandmaintain•Costefficientsolution•Completepackagefromasinglesupplier•MotoWeld-SR350isspecificallydesigned

for robotic welding

Scope of delivery:•SR350powersource•Wirefeeder:0-18m/min.•Torchneck•Collisionsensor•Controlanaloguevoltages(2channels)•ManualinEnglish

Plug & Play robotic welding system “MotoWeld-SR350”

“MotoWeld-SR350”

is a plug & play solution for gas-cooled

MIG/MAG welding.

Seven MOTOMAN robots, coupled to-gether via a single shared controller, co-operated in a spectacular show cell. This featured MotoWeld SR350, a special Plug & Play solution for air cooled weld-ing. This kind of “synchromotion” system which, in practice, can integrate eight fully synchronised MOTOMAN robots with up to 72 axes, offers distinct advantages over individually controlled robots: without the need for major programming effort, it enables the synchronised operation, or parallel motion, of robot and positioner. Welding and handling processes are carried out in a single step. The quantity of fixtures required is greatly reduced. At the same time, the highly flexible system guarantees maximum process reliability.

Two high-speed MOTOMAN VA1400 welding robots also form an integral part of the exhibited multi-robot system. This model is one of the world’s first industrial robots for the arc welding sector with se-ven controlled axes. Thanks to its stream-lined design, the flexible 7-axis robot has extremely high freedom of motion, even in highly confined workspaces. At the same time, the robot density in the manufacturing cells can be considerably increased. Furthermore, the VA1400 supports jigless welding applications: co-operating robots perform the entire handling and welding process without the need for positioners or additional fixture systems. This enables even more efficient produc-tion processes.

YASKAWA at Blechexpo/Schweisstec 2011 (Landesmesse Stuttgart, 06–09 June 2011, Hall 6, Booth 6512)

Fully synchronised for greater efficiency in the welding process At this year’s Blechexpo/Schweisstec, YASKAWA focused on multi-robot technology and solutions relating to the trend topic “jigless welding”.

TRADE FAIR 19

YASKAWA at MEDTEC Europe 2011 (Landesmesse Stuttgart, 22–24 March 2011, Hall 8, Booth 8-157)

Automation on the advance in medical technology YASKAWA exhibited at the MedTec trade fair in Stuttgart for the first time, from 22 to 24 March 2011, at the shared booth of the VDMA trade association Robotik + Automation. A total success!

During the four days of the MedTec fair, visitors could witness that YASKAWA, with its broad product range, is able to offer suitable robotic automation solutions for existing and future problems in the field of medical technology. Since the medical technology branch is just at the threshold of a wave of intensive automa-tion, there was a great deal of interest. On show was the compact MOTOMAN MH5 robot which offers maximum per-formance despite its minimal space re-quirements and low procurement costs. Areas of application include laboratories and research facilities where samples have to be processed and tested. However, MOTOMAN robots are also utilised for tasks in the fields of medical technology and pharmaceuticals outside the laboratory.

A MOTOMAN MPK2 can be used, for example, to stack medicines carefully into cartons. These can then be packed at high speed onto pallets using a MOTO-MAN MPK50 or MPL100. In addition to laboratory work and the packaging of medicines and other medi-cal products, robots can also be used in

the field of physiotherapy. YASKAWA has many years of experience in this area. Having branched out into the fields of medical technology and pharmaceuticals years ago, the many enquiries in this sector regarding specific tasks show that YASKAWA has established itself as the competent automation partner.

The high-speed, 7-axis MOTOMAN VA1400 robot was one of the exhibits that could be experienced live at YASKAWA.

TRADE FAIR20

At interpack 2011, YASKAWA turned the spotlight on robotic-solutions for primary and secondary packaging and palletizing. A particular highlight at the booth was the MOTOMAN MPP3 delta robot, making its worldwide debut at the trade fair. The new development performs versatile picking tasks at the start of the packaging chain. The 4-axis robot with parallel kinematic system combines the speed of the delta design with a high payload capacity and a large working range. Also a topic at the booth: the current, steadily increasing demands from industry for greater cost and process efficiency. YASKAWA is responding to this trend with a wide ranging product portfolio and in- tegrated total solutions: MOTOMAN is enabling machine and system builders in the packaging industry to cover the entire PPP process with high quality products from a single source. The product range, designed with a view to minimal space requirements and maximum speed, enables the conception of extremely compact complete solutions. The result:

greater system profitability due to reduced space requirements. Furthermore, MOTO-MAN robots with the “Green energy function” are equipped with energy-saving technology.

A picking-packing cell at the booth illus- trated how such topical robotic solutions can be implemented: the MPP3 delta robot and an MPK2 robot work together in the show cell. A camera, the MOTOpick user interface and a complex conveyor belt monitoring system complete the solution. With this so-called “double conveyer function”, products arrive on one belt, are detected by a camera, are shared between both robots through the MOTOpick soft-ware and deposited on a second conveyor. The cell thus emphasises both the combi-nation of software with camera and robot, and also the performance of the robots and the overall package. In addition YASKAWA presented the per-formance of the fast MPK50 packaging robot in an application palletising boxes at interpack. Furthermore, visitors to the trade fair could witness just how easy and user-friendly operation of the DX controller really is by programming an MH5 robot.

YASKAWA at interpack (Düsseldorf, 12–18 May 2011, Hall 16/Booth A45)

Trend topic: Cost efficiency and process efficiency At interpack 2011, YASKAWA turned the spotlight on robotic solutions for primary and secondary packaging and palletising. A particular highlight at the booth was the MOTOMAN MPP3 delta robot, making its worldwide debut at this trade fair.

Standardised implementation of complete packaging lines with the MPP3 and MPK2.

Impressions of the trade fair booth at interpack 2011.

TRADE FAIR 21

Interest in the new MPP3 delta robot and in picking and packing with the MPK50.

Trade visitors were able to hear explanations about the MH5 and had the opportunity to try programming it.

Servo and inverter drives from the Drives & Motion Division.

22 TRADE FAIR

“In the field of robotics, we now cover the entire product spectrum for the packaging market,” says Alexander Steiger, Sales Man- ager for Robots & Products at YASKAWA, retrospectively explaining the company’s participation in this particular trade fair. “Our presence at interpack was the logical consequence.”

Innovation at the trade fair: MPP3 delta robot The particular highlight at the company’s booth was the new MOTOMAN MPP3 delta robot which made its live debut here. “With the MPP3, it was not just another trade fair innovation that we were presen-ting, but the world’s fastest robot in opera-tion”, adds Steiger. Another topic at the interpack booth was overall solutions from both YASKAWA divisions – Robotics and Drives & Motion. “We were confronted with a number of specific applications in the fields of biscuit, production and packaging, which spanned both divisions,” explains Steiger. “This opened up new approaches for new de- velopments.”

Potential According to observations made by YAS-KAWA, the potential for robotic packaging solutions remains far from fully exploited. This view has been confirmed by many trade fair discussions with both domestic and international customers. “Many tasks in this industry are still performed man- ually. They can be implemented far more efficiently with really simple automation solutions that have a fast return on invest-ment,” asserts Alexander Steiger.

Summary “Interpack 2011 was a complete success for us,” concludes Steiger. “We had a large stream of visitors with a high proportion of them coming from abroad. It is thus not only our workforce here in Germany that profits from the positive response, but also our colleagues in Europe and overseas. We returned home with good results: on the one hand, a set of high-quality contacts, and on the other hand, confirmation that we have developed the ideal robot for the packaging market.”

YASKAWA looks back on a effectively interpack trade fair (Düsseldorf, 12–18 May 2011, Hall 16/Booth A45)

“Rapid development in the packaging market” YASKAWA looks back on a effectively interpack premiere: the company, which manufactures MOTOMAN-brand industrial robots, exhibited at the international trade fair for the packaging industry for the first time. Innovation highlight: the MOTOMAN MPP3 delta robot.

The MOTOMAN MPP3 delta robot.

23EVENT

The slogan chosen for the event, “Go Robotics”, could not have been more apt. Attended by more than 100 participants, primarily from the aerospace industry, but also from the automotive industry, particu-lar interest at the event was focused on automation solutions for tasks that were previously difficult to automate or had not been automated at all. In high-quality pre-sentations, the speakers presented pion-eering solutions and promising technolo-gies for precisely this kind of application.There are numerous reasons for the fact that relatively many tasks in the aerospace sector are still carried out manually and that automation is only slowly making in-roads. Alexander Steiger, Sales Manager for Robots & Products at YASKAWA Europe GmbH, attributes this, in part, to the fact that there is significantly less demand for robots than in the automotive industry, which makes many manufacturers reluc-tant to commit themselves too heavily in the aerospace sector. “A second, even greater problem, is often the program-ming for aerospace applications, which are doubtless highly interesting. These are dominated by free-form surfaces which require extremely complex programming when using conventional methods,” claims Steiger. In partnership with software spe-ialist Cenit, YASKAWA offers integrated, automated processes that enable the ma-nufacture of complex components directly from the computer, faster and more cost-effectively than ever before.

From theory to practiceIn his presentation on optimized offline pro-gramming as a prerequisite for cost-effective automation, Dipl. Ing. Nikolai D’Agostino, from Cenit AG, explained what such pro-cesses and solutions might look like in practice. D’Agostino showed how syste-matic process orientation and integration into the industry-standard CATIA V5 sys-tem can result in considerable simplifica-tion and integrated data processing. With open system architecture, the offline pro-gramming of a wide range of handling and machining processes can be implemented without major effort.

Later in the event, the trade visitors had the opportunity to see for themselves the practical advantages of the sketched solu-tions implemented in the exhibits. Alexan-der Steiger had the following to say on the matter: “Even industry insiders were sur-prised at just how easy MOTOMAN robots are to program thanks to their DX100 con-troller in conjunction with the superior software solution from Cenit AG. Thanks to Cenit, the offline programming of highly complex 3D paths is quicker and easier than ever before. The combination of MOTOMAN robots and Cenit software is a high-performance process solution that is predestined for complicated applica-tions in the aerospace sector and without which certain tasks would simply not be possible.”

Versatile range of potential applications for robots At YASKAWA, typical fields of activity for robots in the aerospace industry include deburring, hemming, stitching, riveting, waterjet cutting and non-destructive test-ing, just to name the most important examples. Given the increasing use of high-tech materials in aircraft construction, such as glass fiber-reinforced plastic, the need for automation is increasing accordingly. This is opening up a whole new range of interesting fields of application for robots.YASKAWA’s market analyses were con-firmed by the great interest of the visitors from the aerospace sector in the automation of innovative manufacturing processes.“The best part,” according to Steiger, “is that YASKAWA, together with Cenit AG, is already in a position to offer turnkey and

process-reliable solutions for the automa-tion requirements that are being created.” Additional advantage: the new solutions for the new markets also benefit from the decades of experience of the YASKAWA (formerly MOTOMAN) team in conven-tional systems engineering and from the expertise acquired from thousands of completed projects. This combination of traditional systems engineering know-how and the new possibilities offered by offline programming is jump-starting the auto-mation of complex processes in the aero-space industry – in accordance with the slogan “Go Robotics”.Photo: Ralf Högel

Technology show at YASKAWA Europe a complete success

Focus on the aerospace sectorAt a technology show in February 2011, robot manufacturer YASKAWA underscored the fact that the company’s expansion strategy does not shy away from branching out into new markets. The aerospace industry is one sub-sector with tricky applications for which YASKAWA already offers suitable solutions.

Forthcoming trade fairs

Alexander Steiger, Head of Robots & Products.

Motek 2011Landesmesse Stuttgart10 to 13 October 2011Hall 7 / Booth 7205

Automatica 20125th international trade fairfor automation and mechatronicsNew Munich Trade Fair Centre22 to 25 May 2012www.automatica-munich.com

SPS/IPC/DRIVESTrade fair & conferenceNuremberg22 to 24 November 2011Hall 2 / Booth 131

Fakuma 2011Friedrichshafen18 to 22 October 2011Hall A7 / Booth 7208

VORWORT • INHALT0

MOTOMAN near to you

www.yaskawa.eu.comrobotics@yaskawa.eu.com

Headquarters

Robotics

Division

YASKAWA Academy and

sales office Frankfurt

YASKAWA Europe GmbH

Robotics Division

Hauptstraße 185

65760 Eschborn

Germany

Fon 0049-61 96 - 777 25 - 0

Fax 0049-61 96 - 777 25 - 39

YASKAWA Europe GmbH

Kammerfeldstraße 1

85391 Allershausen

Germany

Fon 0049-81 66-90-0

Fax 0049-81 66-90-103

YASKAWA Electric CorporationJP 2-1, Kurosaki-shiroishi

Yahatanishi-ku Kitakyushu-shi 806-0004 +093-645-8801

YASKAWA GroupA YASKAWA Austria

Schwechat/Wien +43(0)1-707-9324-15

CZ YASKAWA Czech s.r.o. Rudná u Prahy +420-257-941-718

D YASKAWA Europe GmbH Robotics Division Allershausen +49-8166-90-0

YASKAWA Europe GmbH Headquarter Eschborn +49-6196-77725-0

E YASKAWA Ibérica S.L. Sant Bol de Llobregat +34-93-6303478

F YASKAWA France SARL Saint-Aignan-de-Grand-Lieu +33-2-40131919

FIN YASKAWA Finland Oy Turku +358-(0)-403000600

GB YASKAWA UK Ltd. Banbury +44-1295-272755

I YASKAWA Italia s.r.l. Torino +39-011-9005833

IL YASKAWA Europe Technology Ltd. Rosh Ha’ayin +972-3-9004114

NL YASKAWA Benelux B.V. EB Son +31-40-2895500

P YASKAWA Ibérica S.L. Aveiro +351-234-943900

RUS YASKAWA Nordic AB Moskva +46-480-417-800

SE YASKAWA Nordic AB Torsås +46-480-417-800

SI YASKAWA Slovenia Ribnica +386-1-8372-410

DistributorsBG Kammarton Bulgaria Ltd.

Sofia +359-02-926-6060

CH Messer Eutectic Castolin Switzerland S.A. Dällikon +41-44-847-17-17

DK Robotcenter Danmark A/S Løsning +45-7022-2477

EE RKR Seadmed OÜ Tallinn/Estonia +372 68 35 235

GR Gizelis Robotics Nea Kifissia +30-2106251455

H Flexman Robotics Kft Budapest +36-30-9510065

Rehm Hegesztéstechnika Kft Budapest +36-53-380-078

N Optimove as Lierstranda +47-32240600

PL Integrator RHC Sp. z o.o. Toru n +48-56-6519710

TR Teknodrom Robotik Otomasyon San. Tic. Ltd. pti Gebze/Kocaeli +90-262-678-88-18

ZA Robotic Systems SA PTY Ltd Johannesburg +27-11-6083182