ABB Robotics has gone on a streak of packaging robots with controllers and/or software to simplify the adoption of robots in specialized applications, such as welding and cleanroom. The industrial robot maker's latest move is a package that puts together hardware and software for high-speed, end-of-line palletizing.
The PalletPack 460 is a pre-engineered package that includes the company's new IRB 460 robot, which was specifically designed for high-speed, end-of-line palletizing applications. The package aims at making it easier for integrators to specify and design palletizing systems. It's also designed to lower the barriers to entry for end users into the adoption of robotic palletizing automation.
A robot package that puts together hardware, including the 4-axis IRB 460 robot shown here, and software for automating high-speed, end-of-line palletizing is easier to program and integrate into existing lines. (Source: ABB)
PalletPack 460 consists of fully documented, integrated hardware to lower overall project costs and reduce engineering setup time by making it easy to integrate and program the robot and its controller.
The function package comes in either a high-speed bag palletizing version or a compact, end-of-line case palletizing version. It includes an IRB 460 palletizing robot, a Flex-Gripper end-of-arm tool, an ABB control PLC, a Jokab safety PLC, PalletWare support software, and user documentation. It also includes the ABB FlexPendant, which is the standard ABB Robotics human-machine interface (HMI). The FlexPendant has a graphical interface with four screens for pallet and pick setup, pallet pattern setup, path profile edition, and movement edition.
Simplified programming is one of the package's key features, as it is in ABB's ArcPack Lean 1410 package for welding, which has an interface simple enough to be sold off the shelf. While the PalletPack 460 may not be that simple, its programming wizard makes the programming very similar to that used for a traditional PLC. This makes it possible for PLC programmers who don't have experience in programming robots to program the system.
"PLC programming is a preferred programming language at a majority of manufacturing and logistics facilities," said John Bubnikovich, executive director of marketing and business development for ABB Robotics, in a press release. "The PalletPack 460 eliminates the need for special robot programming know-how, and provides complete cell control in one function package."
The 4-axis IRB 460, which ABB claims is the fastest known palletizing robot available, has a reach of 2.4m and a payload capacity of 110kg. It can achieve up to 2,190 cycles per hour with a 60kg load. Its compact, 100.7cm x 72.0cm footprint lets pallets be placed closer to the robot, and makes it easier to integrate it into existing packing lines.
Al, when you talk about the goal of eliminating the need to write robot application software, what does that mean? Does the user just answer a few software-based questions, fill in a few parameters, and then go? Seems like the robot's motion wouldn't be very ideally-suited to the task that way.
While there are some application-specific packages being developed with the goal of limiting user programming, the bigger trend in automation software is the development of software objects. These objects are reusable, configurable functions that are supported by powerful integrated development environments but still require programming expertise. Of course, companies that build specific types of machines have their software base and expertise in specific application areas but it doesn't go as far as the ABB solution which is offering really a turnkey package for palletizing.
Yes, Apresher, it seems the goal for much of the new automation hardware is to relieve the end user of customer programming. So much of the new product introductions seemed to be designed for quick and easy deployment. Not a bad trend.
ABB is leveraging its experience in writing palletizing applications with this software and robots/grippers specifically targeting these types of projects. By putting the major focus on ease of use, this approach reduce the need for custom programming but I would be surprised if they couldn't make adjustments to fit a specific customer requirement. This is a very intriguing product that has a goal of virtually eliminating the requirement to write robot application software for the user. Definitely a trend; the key is application software that can be deployed to meet a range of customer needs using the standard software product.
I'm not sold on this being a great idea. There are nuances to robot programming that cannot be included into a software package. Proper selection of motion type, termination type, look-ahead, etc. are part of robot programming. Programming a robot is easy. Programming a robot well isn't.
The best examples that I have are with CNC machining. I saw a demonstration of an aluminum part being machined, and I could hear the machine was being over-driven. After the cutting cycle ended, I reached into the machine to inspect the chips to see how hard the cutter had been working. I pulled out a blob of aluminum. The software had allowed the tool to be driven so hard that it melted the aluminum instead of cutting it. I saw another application where the software allowed a 9/16 drill bit to be plunged through 1/2 thich aluminum. The proper sequence would have been: center drill, pilot drill, finishing drill. Oh, the reason that I was there was they had destroyed the bearings in the spindle because the drilling reaction load was too large.
This robot package adds to a recent trend in automation -- devices that include the intelligence inside, making it easier for users to deploy the package. We're seeing this in a wide range of automation equipment. This is the first time I've seen it with robotics. It's a great idea -- make the device or package more intelligent on the inside and less complicated on the outside.
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