For years, robots have represented the cutting edge in manufacturing, and until recently, they have been viable only for manufacturers with complex needs and big budgets. But today, robotic solutions are becoming more versatile and easier to attain. They are a practical solution for a broadening range of manufacturing applications – from vision-directed, high-speed pick-and-place packaging, to high-precision automotive assembly and semiconductor handling.

 
Increased Demand for Cost-effective Robotic Control

Technology and market trends are helping bring robots to the forefront of machine design, including: Flexibility demands — Constantly shifting consumer preferences put increased pressure on manufacturers to offer a greater variety of product styles, shapes and sizes. A programmable robot that can perform different tasks with quick changeovers helps end users produce this variety for less money and using less space.
Worker safety imperative — Manufacturers around the world are increasingly focused on corporate responsibility and implementing initiatives to operate more responsibly, including making sure manufacturing operations protect the company’s most important asset — its workers. Robotics help eliminate the need for people to perform dangerous, dirty or routine tasks, helping create a safer and more ergonomic workplace.
Declining hardware costs — Over the past 10 years, more robot sourcing options have entered a competitive market, helping lower the cost of the hardware used for robots. Machine builders now have more options for adding robotic applications to their machinery at a more reasonable price.
Quality improvements — The increase in robot sourcing options also has helped drive improvements in the quality of the hardware and controls available. Engineering advancements have solved many of the issues that used to plague robotic applications such as twisted cables, excessive tooling or limited sizing options. Additionally, peripheral systems have improved, including vision systems which are now capable of higher line speeds, making a turnkey robotic solution a better possibility.
Robot Integration — Dedicated or Multi-discipline Control?
Consider the complexity and potential process integration issues that can occur when using a dedicated, special-purpose robot controller. A dedicated controller requires an extensive amount of peripheral technology and hardware to operate, including:
Separate control cabinets consuming valuable floor space
Complex and costly network and/or discrete interface
Servo drives, motors and cables that are different from those used on the rest of the line
Separate programming and configuration software than what is used for the line controller
Interfacing the robot controller to the main line controller using a discrete or network interface can result in lower system performance, additional program complexity, and increased solution cost. Other issues include additional integration, and training time and costs, extra spare parts, limited or inconsistent safety solutions, and limited ability to select best-of-breed components.
Fortunately, machine builders can leverage a more practical control solution for robotics by incorporating robotic control directly into the main system’s programmable automation controller (PAC). Rockwell Automation addressed the industry’s need for one common hardware and software architecture to support multiple control disciplines with the Rockwell Automation Integrated Architecture™ framework. The Allen-Bradley® ControlLogix® family of PACs and the Rockwell Software® RSLogix™ 5000 programming software allow manufacturers to integrate simple, multi-axes robot control into the main Logix control platform.
A few of the many advantages to having an entire manufacturing line, including the robot, controlled by the Logix platform, include:
Streamlined design — Reduced control components lower overall system costs and help optimize floor space for end users. Further, end users benefit from a more synchronized and efficient production line when machine builders leverage the ability to use common Rockwell Automation products throughout the line, such as I/O, servo drives, motors and safety products.
Simplified programming — One software package is used to program and configure the robot and the rest of the control system. An extensive library of robotic application add-on instructions (AOIs) within the RSLogix software make robot integration fast and easy.
Enhanced performance — With all system control elements residing on the same hardware chassis and the same control architecture, faster communication and data manipulation is possible than with a system that employs multiple controllers. This highly synchronized and efficient production line helps companies manufacture, package and ship more goods at a lower cost and with greater accuracy. Also, integrated control and the ability to use one common hardware and software architecture helps improve machine flexibility and can reduce changeover time, thus helping end users to more easily meet certifications and industry regulations concerning software validation and traceability.
“Reduced programming efforts and savings in design time are some of the key benefits Bradman Lake immediately received by choosing Rockwell Automation solutions. We obtained a seamless integration between servo-motion and logic controllers, and achieved true flexibility in setting up the control hardware, as well as in programming and diagnostics.”
— Nick Bishop, vice president of sales and marketing, Bradman Lake Inc.
::Robot 101
Just as there are multiple tools in a tool box, multiple robotic formats exist that are suited to different application requirements:
SCARA robots are best used in dispensing, pick-and-place and gang-picking applications for assembly and packaging where loads are moderate and high precision accuracy is not the top priority — for instance, in assembling a cell phone to place covers or buttons in the right location. SCARA robots are appropriate for plane-to-plane moves and have a small footprint, making them an ideal choice for manufacturers with space constraints.
Delta robots also are useful in pick-and-place applications for assembly and packaging when the load is light — typically less than one kilogram — like candy or lids for jars, and they are capable of operating at very high speeds. Delta robots are ideal for plane-to-plane moves. However, they are only able to move up and down relatively short distances in the Z axis — typically less than 100 millimeters.
Articulated arm robots are ideal for applications with a large work envelope and heavier payloads. In addition to plane-to-plane moves, they are also well-suited to painting or welding applications where movement over and under objects is necessary.
Cartesian robots are frequently used in everything from life sciences applications to cartoning, dispensing, palletizing and large assembly projects. A Cartesian robot is a good choice for any system that has clearly defined x, y and z axes.

::Product and Service Highlights
Allen-Bradley Guardmaster® SafeZone Multizone Safety Laser Scanner
The SafeZone™ Multizone safety laser scanner is a versatile, cost-effective and rugged solution that is well suited for a wide range of industrial safety applications up to Category 3. The Type 3 optoelectronic device protects personnel or equipment by detecting objects or persons in its sensing field. When an object is detected, the SafeZone Multizone scanner sends a stop signal to the protected machine. The combination of enhanced performance with simple installation and setup makes the SafeZone Multizone laser scanner the ideal solution for robotic and assembly cells. More information
 ::Allen-Bradley Kinetix 6000 Safe-off Servo Drive

This servo drive includes a peak enhancement feature that allows machine builders to take full advantage of the peak operating range of the motor, resulting in higher value of the motor/drive combination. This enhancement will permit a smaller frame selection for integrated axis modules and axis modules in highly demanding applications, allowing machine builders to reduce the hardware cost of their system and the panel space required to support their motion application. Motion processes that require fast acceleration and deceleration for a limited duty cycle, such as robotics, will benefit the most from these enhancements. In summer 2009, the Kinetix® 6200 Safe Speed servo drive also will be available, offering robot manufacturers and integrators easier safety integration and reduced wiring. More information
Kinetix Accelerator Toolkit
The Allen-Bradley Kinetix Accelerator Toolkit provides a range of tools and standard design templates to help OEMs streamline the design, programming and installation of an integrated robotic motion control system. A key feature of the Kinetix Accelerator Toolkit is its ability to accommodate a wide range of Allen-Bradley control system hardware, including PanelView™ operator interfaces and Logix controllers. Customer studies have shown as much as 50 percent reduction in design time when using the Kinetix Accelerator Toolkit. More information
Motion Analyzer
Motion Analyzer software from Rockwell Automation helps minimize design risk and speed time to market by providing tools that help OEMs analyze design alternatives for robotic motion control applications. In addition to its sizing, selection, optimization and simulation capabilities, Motion Analyzer software offers performance evaluation features including ratio, torque and tolerance analysis. More information

Allen-Bradley MP-Series Integrated Multi-Axis Stages
With a flexible design that accommodates positioning the stages from either above or below the work piece, the pre-engineered MP-Series™ Integrated Multi-Axis Stages offer an out-of-the box experience for users looking for simplification, reliability or performance improvements from their multi-axis positioning system. With the ability to carry a payload of up to 25 kilograms while achieving an acceleration of 1g at maximum payload, the stages provide precise two dimensional linear motion capabilities for assembly, dispensing, inspection, packaging and cutting applications. More information
Encompass Partners
Rockwell Automation not only offers the most advanced integrated robotic control solutions; the company also aligns with leading robot and machine vision suppliers through the Rockwell Automation Encompass™ partner program. The partnerships help machine builders skip the step of searching for the best, most compatible robot and machine vision solutions to meet their specific application requirements.
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