Robotics Embedded robotic functionality for packaging machinery

Robotics
Robotics_EN_0704 VM08103-001
Embedded robotic
functionality for
packaging machinery
Trend
Integration of robots into packaging processes
Secondary Packaging
Production
Robotics
Primary Packaging
3
Robotic functionality is a clear trend in packaging
machinery. Now, instead of third party robots and
proprietary controllers, OEMs are designing modular
machines that are essentially clusters of robot
arms synchronized to servo-driven belts.
The new designs are replacing conventional
infeed, collating, cartoning, case packing as well
as end-of-line functions with extremely agile robot
modules that are infinitely adjustable to future
format changes.
ELAU’s new IEC conforming PacDrive™ robotic
software library is responsible for enabling this
transformation. Not only does the PacDrive™ automation system eliminate the need for proprietary
robot controllers, it allows builders to focus on
creating innovative robot arm mechanics – without
needing to become kinematics experts themselves.
Conventional
Two different controllers
Ethernet, TCP/IP, OPC, ftp, http, SMS, SMTP
Packaging
machine
control
Robot
control
Motion bus
Robot
Field bus
In/Out
Robot
Infeed
Dual Belt
Conveyor Belt
Motion bus
Infeed
Dual Belt
Conveyor Belt
5
While robots offer great flexibility, conventional robots
use proprietary controllers that incur added costs for
hardware, software, integration, training and support.
The robot is a separate system that requires extensive
effort to synchronize with the machine controller automating the rest of the packaging process. Robot manufacturers each use their own, non-standardized languages that must be learned.
ELAU’s solution replaces this proprietary controller
and software entirely – with a modular software
approach that’s changing the way packaging
machines are designed.
Proprietary robot controller
Multiple programming languages to learn
Extensive synchronization work
Innovative
Single control system with integrated robot functionality
Ethernet, TCP/IP, OPC, ftp, http, SMS, SMTP
Scalable PacDriveTM Controller
with Motion/Logic Control
Field bus: e.g. Profibus DP
In/Out
Motion bus: SERCOS
Infeed
Dual Belt
Grouping
Robot
Robot
Conveyor Belt
Cartoner
Integration of multiple machine components in a modular configuration
Infeed
Dual Belt
Conveyor Belt
7
In the past, it simply was not possible to control multiple robot arms and dynamic packaging processses in a
single controller.
That’s changed. ELAU’s PacDrive™ automation controller is powerful enough to integrate robotics along
with all machine motion, logic, HMI, vision and communications requirements.
Best of all, the robotic functions and kinematics reside
in an IEC 61131-3 conforming software object library.
A single, standardized robotic Function Block simply
runs in the same program controlling the rest of the
process.
That means you can say good bye to supporting proprietary ‘black box’ robot controllers forever.
It also means you’ll save on hardware, electrical cabinet and software costs, improve the performance of
the entire system, and reduce your overall footprint.
Reduced engineering and training
Standardized software library replaces proprietary
'black box' robot controllers
Fewer interfaces, higher performance
A single controller integrates robotics, motion,
logic, HMI, vision and communications
Performance table for robot applications
Standard software
Robots integrated as equipment modules
MES/ERP Level
Line Level
Secondary Packaging
Machine Level
Equipment
Module Level 1
Equipment
Module Level 2
Grouping
Infeed
Dual Belt
Cartoner
Robot
Conv. Belt
Modular software structure with the PacDriveTM template
EPAS-4 automation toolkit:
Integrated robotics
9
In ELAU’s development environment, a preconfigured
program structure, or template, promotes best practices in modular software design.Using this template,
multiple robotic modules can be integrated into the
overall project just like any other machine module.
Programming is simplified by an extensive library of
pre-tested, reusable, IEC-conforming Function Blocks,
including the PLCopen motion function blocks. Programmers can parameterize rather than write original
code for hundreds of functions, including robotics,
which results in consistent and highly maintainable
code.
Access to all variables also simplifies machine engineering and diagnostics. ELAU’s experience implementing
robot functions in packaging machines confirms that
engineering, commissioning and service tasks can all
be significantly reduced as a result.
Easy programming and diagnostics
with the integrated EPAS-4 automation toolkit
– including robots
Convenient access to all variables
No additional software tools
Standard-based programming simplifies training
Robotics library
Powerful and convenient
5th degree polynomial
advanced interpolation
x
Circular
Spline
Linear
Point-to-point
Move
x,y,z
u,v,w
Virtual
master
z
u
v
w
VEL monitoring
ACC monitoring
Master encoder
Axis 1
y
Axis 2
Robot
Kinematics
Axis 3
Axis 4
Axis 5
Axis 6
Move
PTP
Asynchronous
Axis
1
Move
PTP
Asynchronous
Axis
n
11
The robot's trajectory can be easily specified in the
form of points in the range of movement. The complex
conversion of the Cartesian coordinates into the
positions of the individual robot axes is performed
automatically and in real time by the PacDriveTM
software.
z
Centrifugal
acceleration
Resulting
acceleration
Path acceleration
The robot module also includes intelligent online
acceleration monitoring at the tool center point (TCP).
It can also be used for real-time monitoring of centrifugal force on the product in the robot’s gripper,
based on mass and acceleration.
The ‘belt tracking’ function enables the robot to be
synchronized with multiple conveyor belts or external
master axes. For example, the robot can remove
products from one running belt and deposit them
on a different belt.
x
Intelligent acceleration limitation
Circular
Point-to-point
Linear
Motion functions with or without blending
Synchronization of robots with different belts
(belt tracking)
Standard interpolation types with
advanced interpolation functionality
Intelligent acceleration monitoring
Kinematics
All standard kinematics for packaging applications
Portal
Delta 2
Articulated
Scara
Gantry
Delta 3
13
PacDriveTM performs the kinematics for standard robot
configurations, including articulated, gantry, delta, SCARA
and portal robots in up to 6 dimensions. So, there’s no
need to become a kinematics expert to embed a robotic
equipment module into the machine control system.
The developer has a choice of configuring transformation modules for standard kinematics from pre-tested
Function Blocks or designing their own intellectual
property using ELAU's universal transformation module.
ELAU’s library provides Function Blocks for each robot
type, so they can be easily interchanged with no impact
on the rest of the machine control software.
Performs all standard robot kinematics:
gantry, SCARA, portal, articulated, delta
Configurable transformation modules
for standard kinematics
Universal transformation module
for customer-specific kinematics
Benefits
One system –
all the benefits at a glance
Control of packaging machinery with
multiple robot modules in a single controller
Reduced engineering effort
No 'black box' robot controllers
Reduced hardware and software costs
No performance-robbing interfaces
Simplifed integration
Less electrical cabinet spaced required
Better synchronization of robotic and
packaging processes
Standard software for all
machine modules including robots
Simple programming and diagnostics with
the integrated EPAS-4 automation toolkit –
including robots
No additional software tools
Simplified training
Powerful robotics library
Supports all standard robot kinematics:
gantry, SCARA, portal, articulated, delta
Convenient access to all process variables
Modular software structure
using the PacDriveTM template
15
Pester pac automation
Stretch wrapping with integrated pac robot 3 robot cell
“The pac robot could not have been developed without ELAU's robotics
library. Because ELAU covers all the system functions, we can concentrate
on our core task, namely product handling in the packaging process“,
Lorenz Fleschutz,
Head of Software Engineering Department
Wächter Packautomatik
Sorting plant with highly dynamic pick & place robot
“The ELAU robotic functionality and program
structure enabled us to cut our engineering and commissioning workload
by around 25%. At the same time, we doubled the picker's output
from 30 to 60 transfers per minute“,
Stefan Wächter, Chief Executive
Pester pac automation,
PEWO-pack 450 Compact
Cavanna
Robot-based cartoning machine (including infeed, dual belt,
3 robots, conveyor belt)
“The ELAU solution means that we can easily integrate several robotic
modules into the packaging application. All machine modules are
controlled by a single ELAU controller and programmed using a standard
software tool“,
Riccardo Cavanna, Product Development & Customer Relations Director
ARC Advisory Group
”ELAU’s robotic library turned out to be something of a quiet revolution
… A number of packaging machine builders using ELAU’s PacDriveTM
automation system have taken advantage of the software’s modularity
to design modular machines with integral robotics.“
Sal Spada, ARC analyst
Author of Integral Robotics Raises Agility
and Flexibility of Packaging Machinery
Cavanna, Cartesio G35
Contact
ELAU AG
Headquarters
Dillberg 12
97828 Marktheidenfeld
Germany
Phone +49 9391 606-0
Fax
+49 9391 606-300
[email protected]
www.elau.de
Detailed information is available at
www.elau.com/contact
Worldwide in 190 countries
ELAU North America
+1 847 490427-0
[email protected]
www.elau.com
ELAU Switzerland
+41 62 855 20 00
[email protected]
www.elau.ch
ELAU UK
+44 1908 6280-14
[email protected]
www.elau.co.uk
ELAU BeNeLux
+31 6-53949295
[email protected]
www.elau.nl
ELAU Italy
+39 051 62767-11
[email protected]
www.elau.it
ELAU Scandinavia
+46 42 2577 60
[email protected]
www.elau.se
ELAU France
+33 1 6959-1414
[email protected]
www.elau.fr
Subject to change without notice.
All trademarks mentioned in this brochure
are the sole property of their owners.