Video: CT4 High-speed Cartesian Robot

Posted on April 10, 2013 by IAI America

High-speed Cartesian Robot That Shortens Assembly/Inspection Cycle Times by Operating at High Speed, Ensuring High Rigidity and Demonstrating Excellent Straight Moving Performance
High-speed operation with commanded acceleration of up to 3.2 G
(maximum instantaneous acceleration: 4.8 G)

Learn more about the CT-4 at IntelligentActuator.com

Download the CT4 High-speed Cartesian Robot Catalog

Semi-automatic Machine for Inspection and Testing of Connector Application Example

Posted on September 17, 2012 by IAI America

Automotive / Machine Tools

Semi-automatic Machine for Inspection and Testing of Connector Application Example

A semi-automatic machine that performed inspection and continuity testing for a press fit connector used for an automotive sensor, which used conventional air cylinders, now uses ROBO Cylinders
The system process includes:
1. Conveyance unit
2. Press fitting the connector
3. Continuity test & inspection
4. Marking process for parts that pass
By changing to electric actuators, the cycle time has improved by 36% and reduced the running costs by approximately $262,700 over 3 years.

We reduced the costs by approximately $262,700: $44,600 equipment + $216,600 personnel expenses + $1,500 cost of equipment: a total of 3 years.

Notes: Exchange rate: 90 yen = $1, Dollar amounts rounded to the nearest $100

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Machine Loader & Unloader Application Example

Posted on September 17, 2012 by IAI America

Machine Tools

Machine Loader & Unloader Application Example

Actuators	RCP4-SA6C/SA7C RCP2-GRM RCP2-RTCB
Controller	PCON-CA

In the process of machining aluminum parts inside the machining center, ROBO Cylinders have been employed in loading & unloading the work parts.

Traditionally, this task had been done manually but will be automated to increase production. Calculations were performed with regard to production volume and cycle time to determine whether using ROBO Cylinders or air cylinders would be most beneficial for the system. The results as shown in the table below indicate that 100% productivity can be realized with ROBO Cylinders while only 69% productivity can be realized with air cylinders.

Running 12 hours per day (60sec/min x 60min/hr x 12 hours = 43,200 seconds)

The number of work parts produced using air cylinders:
(43,200 seconds x 85%)÷6.4 seconds = 5,737 parts

The number of work parts produced using ROBO Cylinders:
(43,200 seconds x 90%)÷4.7 seconds = 8,272 parts

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LED Light Inspection Application Example

Posted on July 27, 2012 by IAI America

Inspection / Examination / Etc.

LED Light Inspection Application Example

Actuators	RCP4-SA5C
Controller	PCON-CA

The ROBO Cylinder has been adopted into a machine for measuring the intensity of the LEDs which are placed at regular intervals inside the LED fluorescent shape lamp.

To measure the illumination, the slider moves a light meter to each interval of an LED. The measurement results are managed by a personal computer.

Traditionally, the measurements were conducted manually and there was a variation in the measurement position. By adopting the ROBO Cylinder, the accuracy of the measurement position has been improved.

In addition, by automating, the measurement efficiency was also improved by being able to simultaneously measure three LED fluorescent shape lights at a time.

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Pick, Place, and Discharge Machine for Automotive Parts Application Example

Posted on July 26, 2012 by IAI America

Automotive / Machine Tools

Pick, Place, and Discharge Machine for Automotive Parts Application Example

Actuators	RCP2-SS8C: Y-axis RCP4-RA5 (qty:2): Z-axis
Controller	PCON-CA x 3

An orthogonal two-axis robot with Y & Z axes was adopted to pick automotive parts from a conveyor in-feed line, place the part into processing equipment, and then pick & place the part (discharge) to an out-feed line conveyor.

Sequence of Operations:

“A” & “B” (Z-axes) move to the right, “A” picks the work part from the supply side.

“A” & “B” (Z-axes) move to the left, “A” places the work part into the process equipment.

When the process starts, “A” & “B” (Z-axes) move to the right again, “A” picks the work part from the supply side. At the same time “B” will wait until the process equipment is done.

When the process is done, “B” picks and discharges the work part and “A” places the next work part into the processing equipment and the cycle continues.

Air cylinders were previously being used but cannot be sped up because the impact due to stopping is too great.

8,000 work parts were produced per day using air cylinders. Using ROBO Cylinders, the production rate was up to 12,000. The production rate was increased 1.5x.

Also, when the equipment had to stop due to an air cylinder failure, the equipment was down every 10 minutes and was time consuming to fix so it was changed to ROBO Cylinders, and thus limited any downtime due to stoppages.

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Test Tube Dispensing Application Example

Posted on March 26, 2012 by IAI America

Food Processing / Medical / Etc.

Test Tube Dispensing Application Example

Actuators	RCP2-SA7C RCP3-SA5C RCP3-SA3C
Controller	PCON

ROBO Cylinders have been adopted to dispense reagents in chemical inspection equipment.

To prevent dripping the liquid, the plunger is retracted slightly via a pitch feed operation after issuing the liquid by pressing the piston.

Also, returning to the home position due to an emergency stop of the controller is avoided by using the simple absolute type.

Previously, an in-house design was used which took time to create the mechanical design and to program. This effort was reduced and is now possible by using the ROBO Cylinder.

RCP2-SA7C – lateral movement

RCP3-SA5C – vertical movement of the syringe

RCP3-SA3C – vertical movement of the plunger inside the syringe

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Speaker Cover Tab Folding System Application Example

Posted on January 19, 2012 by IAI America

Automative

Speaker Cover Tab Folding System Application Example

Actuator

Controller

(with Internal controller)

Automotive speaker cover tab folding system.

The table top TT has been chosen for this application.

There are 5-10 tabs that were folded manually, which is very labor intensive and of low quality.

By using the TT, the fixture which needs XY movement, can be easily programmed and results in better quality and reduces the cost.

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Coating – Inspection Process – Pick & Place Application Example

Posted on November 10, 2011 by IAI America

Inspection / Examination / Etc.

Coating – Inspection Process – Pick & Place Application Example

Actuator

ICSA3 x 2

Controller

XSEL

Cartesian robots are used for picking and placing parts for the coating & inspection process.

The parts are randomly placed in the work space of the first Cartesian robot, and by using the vision system interface function, the positions of the parts are transferred to the XSEL controller and the parts are pick and placed onto the rotary table.

After the parts are coated and the inspected, the parts are palletized and boxed by the second Cartesian robot.

One XSEL controller is used to control two 3-axis Cartesian robots and the vision system is directly connected to the XSEL controller so the whole system is built without a PLC.

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Container Sealing Application Example

Posted on November 10, 2011 by IAI America

Food Processing / Medical / Etc.

Container Sealing Application Example

Actuator

RCP2-GRHM

Controller

PCON

This operation was previously performed using two air cylinders to heat seal the neck of the container. Since it used two independently driven cylinders, they were not synchronized. Thus, the exact position that they sealed at was inconsistent, it was difficult to apply the same amount of heat each time, and this contributed to product non-conformance.

By replacing the air cylinders with a ROBO Cylinder electric gripper, better quality can be achieved.
1. The heat sealing is more stable due to the finger synchronization.
2. The heat time can be adjusted more precisely.

By replacing with the electric actuator gripper, the approaching speed was increased, and was able to reduce the cycle time by 25% and thus increase production from 2,000 to 2,500 containers.

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8-axis ROBO Cylinder Electric Shaft Coin Demo Video

Posted on October 3, 2011 by IAI America

This display unit uses the electronic shaft function of the XSEL controller to operate one master axis and seven slave axes in an interlocked pattern.

The eight rod cylinders are moved simultaneously under synchronization control to move sheet-shaped work parts up and down.

Since synchronized commands are issued via pulse train control to the controller that controls each actuator, the sheet-shaped work parts do not tilt and a coin balanced on the work parts remain stationary without tipping.

This function is useful in situations where sheet-shaped work parts such as glass substrates are transferred up and down.

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Category Archives: Application Examples

Video: CT4 High-speed Cartesian Robot

Semi-automatic Machine for Inspection and Testing of Connector Application Example

Machine Loader & Unloader Application Example

LED Light Inspection Application Example

Pick, Place, and Discharge Machine for Automotive Parts Application Example

Test Tube Dispensing Application Example

Speaker Cover Tab Folding System Application Example

Coating – Inspection Process – Pick & Place Application Example

Container Sealing Application Example

8-axis ROBO Cylinder Electric Shaft Coin Demo Video