Motoman Robot Handling and Machine Loading Raw Cast Pipe Fittings

Motoman HP20 robot equipped with two parallel-jaw mechanical grippers loads two parts at a time from a 180-degree indexing turntable into a hydraulic trim press.

Summary

Flexible system meets all project goals and objectives. Robot handles all required part types. Actual cycle time achieved is 25-30% faster than requirement. System maximizes throughput by eliminating downtime. System reduces manual labor, and increases safety by eliminating repetitive motion injuries.

Project Challenges

Provide flexible robotic system capable of loading raw pipe couplings into a hydraulic trim press at the required production rate of 4.8-6.9 seconds per pick, depending on part.
Robot will handle four sizes of parts: 19.05 mm x 12.7 mm (0.75" x 0.5") couplings weighing 0.14 kg (0.31 lbs); 19.05 mm x 19.05 mm (0.75" x 0.75") couplings weighing 0.17 kg (0.37 lbs); 25.4 mm x 19.05 mm (1" x 0.75") couplings weighing 0.218 kg (0.48 lbs); and 38.1 mm x 38.1 mm (1.5" x 1.5") couplings weighing 0.567 kg (1.25 lbs). Changeover of gripper fingers and part-holding fixtures will be manual.
Parts will be batch run. Operator will orient parts when loading them into the fixtures and only one type of parts will be in the fixtures at a time.
Reduce the need for manual labor.
Maximize system throughput by eliminating downtime.
Improve operator safety by reducing repetitive stress injuries.

Motoman Robotics Solution

Motoman Robotics provided a flexible HP20 robot system to load parts into the hydraulic punch press, including:
Motoman HP20 robot with NX100 controller.
XOIO1 Discrete I/O Module with 40 NPN optically isolated inputs and 40 outputs (16 with relay contacts and 24 resistor type, all rated at 24V DC).
Motoman 180-degree indexing positioner with 100 kg (220.5 lb) payload and approximately 2-second index time.
Custom mechanical gripper.
(2) Machine loading operator stations – fence-mounted, with thumbwheel program selection and emergency stop, robot enable/disable, robot startup/shutdown, door guard up/down, and lamp test functions.
Cell guarding package that meets ANSI/RIA R15.06-1999 safety standard. Includes 2.44-m (8') H woven-wire perimeter safety fence, two access gates with positive-break safety switches, and three-color status beacon.

Fixtures/Tooling Details

Motoman Robotics provided the custom end-of-arm tooling for the robot, consisting of two parallel jaw mechanical grippers. The gripper was designed to handle parts two at a time. Extra jaws (changeable gripper fingers) enable the robot to handle all required part sizes. Tooling includes gripper open/closed sensors. Gripper includes electrical and pneumatics package. Motoman integrated the Customer supplied fixtures designed to allow the robot to pick up two parts at a time.