Dr Michael Wenzel, Managing Director of Reis Robotics and chairperson of the advertising and press committee of AUTOMATICA Photo: MM Archive

Together with VDMA Robotics + Automation and the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA), AUTOMATICA has created the new joint initiative "Green Automation". The initiative will be presented at AUTOMATICA 2010 for the first time. The automation industry is taking its responsibility to environmental policy seriously and is actively collaborating in elaborating the vision of a "green" world. This is not only a question of the environmentally-friendly design of production processes, but also of helping resource-saving technologies overall to become established using the innovative solutions of robotics and automation. The initiative will be presented at AUTOMATICA 2010,, which will take place on the grounds of the New Munich Trade Fair Centre from 8 to 11 June 2010, for the first time. "Green Automation" will show the contribution of automation technologies to sustainable management of businesses. Initiative "Green Automation” a major topic of AUTOMATICA 2010 The initiative "Green Automation" will be a major topic of AUTOMATICA 2010. The trade fair and support exhibiting companies in marketing products and production processes for improving sustainability in production. The starting point of the initiative "Green Automation" is the increasing significance of energy efficiency and sustainability in production.

Dr Michael Wenzel, Managing Director of Reis Robotics and chairperson of the advertising and press committee of AUTOMATICA, explained: "Growing interest can be seen in the political sphere and society not to live at the cost of future generations and to reduce consumption of resources noticeably and in the long term without having to make sacrifices of our quality of life. This development challenges the investment goods industry – especially robotics and automation – to create the production technology prerequisites for "green" consumer goods. We have already ascertained a corresponding demand on the market, and consequently it's great that the international trade fair AUTOMATICA is going to focus on presenting "green" production technologies in such a way.

Resource-optimal designed automation technology
Environmentally compatible and energy-saving production only becomes possible with automation technology. Many manufacturers have long been offering solutions for resource optimisation, energy efficiency, reduction of pollutant emissions or energy recovery. In this, it is especially important that all factors are considered with respect to resource efficiency during the complete life cycle of a product or a technology.

The industry sees its responsibility in this area. Thilo Brodtmann, Managing Director of VDMA Robotics + Automation explained: "Intelligent handling of resources will increasingly become a factor success for the competitiveness of producing companies. Modern automation technology can do amazing things here. The manufacturers of automation technology create substantial savings potential for their customers and are the enablers of novel solutions with their engineering skills, which make "green" products possible and affordable in the first place. To make the visions reality, widespread use of the technology is required. "Green Automation" will show precisely that - comprehensively and concretely as never before. "

Automation is the prerequisite for "green" products
The demand for energy-saving technology is increasing due to increasing energy prices and resources that are becoming scarcer. Modern automation solutions enable widespread use of environmentally compatible products and technologies such as photovoltaics. For example, it has already been possible to reduce the manufacturing costs of solar cells substantially thanks to the use robots, assembly technology and industrial machine vision while increasing quality at the same time.

The Fraunhofer IPA sees considerable potential in the area of "green automation": "Automation technology is an essential success factor for competitive production of 'green' products such as solar systems, energy storage or electric vehicles," according to Prof. Alexander Verl, head of the Fraunhofer IPA. "But automation technology as resource consumer must also be considered. Substantial potential can be realized there both in components and machines as well as on the supervision level."

AUTOMATICA 2010 makes is possible to experience "Green Automation"
AUTOMATICA is preparing to present this topic systematically with the initiative "Green Automation". For example, there will be a "Green Automation" visitor guide to bring together those interested and suppliers directly and specific to topics. In addition, a special exhibition will present the most successful examples of "green" products. "Green Automation" will be a central aspect of all issues at the AUTOMATICA Forum on all days.

Does the work of two: the new IRB 360/1-1600 can, in certain handling areas where previously two robots were needed, take over the tasks of both robots – if the line cycle time permits. Photo: ABB

Large capacity automation solutions are much in demand in the photovoltaic industry. Without the use of  highly dynamic, flexible robots with optimum adaption to the requirements of solar cell and module production, this goal cannot be realised. A system of this kind is the new Flexpicker IRB 360/1-1600 by ABB. This robot rounds off the second generation of Delta Robots by ABB. The Flexpicker IRB 360/1-1600 was designed was specially designed for high speed handling of wafers and cells in solar production, where fast and reliable robots are needed for loading and unloading, often of very delicate materials, in the course of various production processes. In extreme cases, the wafers being handled can be as thin as 160 µm. Robots from the ABB Flexpicker family have in the meantime been integrated in more than 2500 installations. The chief characteristic of these robots continues to be their enormous speed. Despite the extremely high acceleration of up to 15 g (15 m/s²) and speeds up to 10 m/s, precise positioning, path accuracy and high reliable are not compromised.

New Flexpicker designed for larger working areas
The advantages of the Flexpicker already available on the market have been integrated into the new IRB 360/1-1600 and have been developed further. This includes the three carbon-fibre arms and the fourth axis as a rotational axis. While previous designs for lines and installations reckoned with a working area of 1130 mm, the new Flexpicker, with 1600 mm, opens new dimensions in productions. In this, say ABB, no comparable robot on the market can compete. Where up till now – depending on the size of wafer – as many as six paths within a line could be served, this number has now been raised to ten.

IRB 360/1-1600 can save a second robot
While two robots were previously necessary for certain handling areas, the IRB 360/1-1600 can cover the same area and take over the tasks of both robots – if the line cycle time permits.

Flexpicker IRB 360/1-1600 also takes over special sorting tasks
As result of the large working area, the new Flexpicker IRB 360/1-1600 is also suitable for special sorting work. With speed and agility, it sorts solar cells into up to 50 different categories.
As an option, the Flexpicker can also be supplied with the Pickmaster software developed by ABB. Via the image processing integrated into the motion control, the robot recognises the position of the cells distributed randomly over the transport belt. For such tasks, it is thus possible to use one or up to eight robots in parallel.

The Robots are flexibly adaptable for various handling tasks
Without complex construction and development work, the new robot can be adapted quickly to the most varied demands in the handling of wafers and solar cells. According to ABB, even after-thoughts can be realised quickly and efficiently.
For line and installation constructors, the IRB 360/1-1600 robot opens up new conceptual approaches, as tasks can be bunched due to the larger working radius. The Flexpicker IRB 360/1-1600 is available in autumn 2009.

In Hamburg, Bosch Rexroth presents products for all stages of solar production. Photo: Bosch Rexroth

The automation specialist Bosch Rexroth, Lohr am Main, is surging ahead with its focus on systems for the solar industry: in a permanent team, specialists are bundling application know-how for control systems, electric drives, pneumatics and mechatronics, as the firm informed us during the 24th European Photovoltaic Solar Energy Conference. The team supports machine manufacturers and users with advice on automation and drive and control technology products. The team is described as having direct access to Rexroth’s world-wide development capacities. Products and systems for the solar industry as building blocks We are told that they can use the firm’s automation building blocks, which include many products and systems specially developed for applications in the solar industry. The pneumatic and electromechanical actuators can be used in any combination, while all physical dimensions are designed for interconnectibility; these qualities are said to raise the degree of freedom for tailor-made handling systems at all stages in solar production. On the level of control systems, Bosch Rexroth describes itself as combining SPS, motion and robotic functions in one piece of hardware, basing the concept on open interfaces and programming standards such as IEC 61131. It is said that this enables cost-efficient standardisation of world-wide production networks at the automation level, even given varying regional requirements.

Energy efficiency reduces costs in solar manufacture
We are told that systems optimised for energy efficiency lead to lower production costs for solar modules. In pneumatics alone, the energy consumption can be reduced by up to 55% by processing  and regulation according to demand. It is claimed that re-use of brake energy throughout and low-weight linear technology reduces the power consumption in the electrical drives by a similar percentage.

The firm says that movement patterns designed with the fragility of solar cells in mind and non-contact grips prevent damage to the solar cells. They have designed the transport system TS Solar for gentle transport of the large and delicate photovoltaic modules. A further contribution to increased productivity is said to be provided by safety functions integrated into the drive system. They reduce the time required to restore normal running of machines after manual intervention and thus boost significantly the availability of production lines.

This Laser Class 1 one-way photo-sensor recognises securely the smallest parts down to even 0.28 mm, making itself the right choice for demanding positioning tasks. Photo: Balluff

The miniature optosensors in the BOS Q08M series with their robust, cubic metal housings appeal, according to Balluff, because of their compact exterior dimensions and their high precision. These optosensors are said to be suitable wherever components with small weight and dimensions and highest precision are required. As examples, the firm mentions robot grip arms and mini-grips. New members of this mini-opto family are a one-way laser optical barrier and a fixed-focus variant. One-way laser optical barrier for demanding positioning tasks The one-way laser optical barrier, Laser Class 1, recognises securely the smallest parts down to even 0.28 mm, making it the right choice for demanding positioning tasks, the firm tells us. At the same time, this sensor with its precisely bundled laser beam and a working range of up to 3 m is also the optimum solution where one needs to “see past” machine parts in confined spaces, they say. The new fixed focus variant is based on the latest pinpoint technology and, with its operating distance fixed at 50 mm, it is particularly easy to put into service. The focused light beam enables precise positioning and prevents mutual interference when sensors are placed next to each other.

A sensor that recognises objects independent of colour, form or surface
According to Balluff, an extremely low grey scale value shift means that this sensor recognises objects independent of their colour, form and surface. Objects outside the control area are securely suppressed. The one-way laser light barrier functions as a closer and is supplied with a PNP output. The fixed focus variant is available with either NPN or PNP output, bright- or dark-switching, and in optional cable or pigtail variants. Connection is made in all cases via a three-pole M8 plug.

Sensors with clamp fitting can be mounted flush with aluminium profiles
Matching these sensors, there is now also a patented clamp enabling rapid positioning of the sensors flush with aluminium profiles, Balluff inform us. The clamp, fitting both Item and Bosch profiles, is simply inserted directly into the groove from above and fixed level with the turn of a screw.
Because of its bomb-proof fitting, these sensors are suitable for the first time for applications which until now have been the domain of the fork light barrier, particularly where suitable intermediate sizes have always been misssing.

The robot palletising installation requires only 16 m2 space including feed and removal.

Composite paper and aluminium sacks are not only to be placed on pallets, but the pallets are also to be put in an outer box. A portal robot capable of handling 150 kg masters this task with a specially developed grip. Sack palletisation can be carried out not only with portal robots, but also with layer palletisers or bent-arm robots. The portal robot, however, offers decisive advantages regarding the maximum number of pallet positions served and their accessibility, including dealing with different pallet heights and, above all, with a covering box presenting the product for sale. The firm Frunol Delicia can look back on a tradition of now more than 190 years in the market sectors plant protection and pesticides. It is thus one of the most experienced medium-size chemical enterprises operating independently in these areas, being notably a market-leader in the area of rodenticides.

Frunol Delicia has now automated its sack palletisation and given the Rober Industrieroboter GmbH the task of installing a portal robot system. The Genix robot series with a handling load of 150 kg can achieve an acceleration of over 6 m/s² with speeds in all axes of more than 4 m/s. The reach extends from 4 m in length and breadth to 8 m in breadth and more than 40 m in length even with pallet heights over 2.4 m. In the Genix xp version (xp:expanded), breadths of even 15 m can be attained, which predestines this model for storage applications. The Gigant range of robots offers high handling loads of 300, 500 and 1000 kg.

In this application, composite paper and aluminium sacks with contents weighing up to 25 kg can be palletised. A particular challenge is presented by the need to palletise the sacks in an approximately 1.2 m high outer box presenting the product for sale. The pallet formats CP1 and CP2 and also a display pallet (half Euro pallet) are used in conjunction with the covering box placed over them. With the CP1 and CP2 pallets, an additional cardboard tray is placed over the bottom layer for protection, and here again accurate palletisation is called for. Further intermediate layers of paper have to be incorporated for stability. The desired pallet height should not exceed 1.8 m.

Leaving the bagging unit, the sacks are presented to the robotic palletising installation. The process relies on a Genix robot with handling load of up to 150 kg. This robot, constructed on a building-block system, possesses the necessary flexibility. The robot requires an area of only 16 m² including feed and removal. Because the spatial limitations and flexibility were key factors in the choice of robot, a portal robot was selected.

As control system, an RO-ENC66 is used. It combines path control and SPS in one system. With communications interfaces such as Ethernet TCP/IP for connections to all standard control systems, and CAN-Open for linking to the digital drive booster as well as to fieldbus connectors and fieldbus-compatible equipment such as barcode readers or displays, this system is predestined for use in robot installations with distributive control structures. During development, particular importance was attached to the integrated diagnostic facility, which informs the operator precisely of errors. Via SPS control, comprehensive data can be presented graphically and visualised using integrated software.
A special point is the packing software Ro-Pack, which calculates the optimum layer configuration when the operator inputs the package dimensions and then transmits the instructions to the robot system. Elaborate programming is thus rendered unnecessary.

One innovation was necessary in the development of the grip, as this could not be larger than the surface area occupied by the smallest product, for the palletised products then have to be fitted into the covering box with its limited dimensions. In the process, pneumatically activated grip arms enfold the sack and open synchronously to palletise the sacks tightly side by side. With suitable measuring systems, the height of the load is monitored so as allow flexible reaction to production variations. In addition, pivoted suction units are incorporated to enable intermediate layers to be introduced.

The production process runs as follows: the operator places a pallet with pallet tray or covering box on the transport mechanism using a hand-operated fork-lift device, and the pallet is fed AUTOMATICAlly to the robot. Now the palletising process can begin. With a grip, the robot takes a sack from the transport mechanism and guides it past an inketjet system for batch marking. Then the palletising follows to a scheme depending on the layer plan. Meantime, on the second pallet path, another pallet can be prepared. The loaded pallets are AUTOMATICAlly transported away from the robot working area along the pallet path. The robot system continues with palletisation, alternating between the two palletisation paths.

The installation of a robot system means that operators can benefit from the elimination of physically demanding work. The quality of the palletising is improved substantially, while other production procedures associated with the palletising can be optimised, raising production efficiency.

ELMAR STÖVE
Elmar Stöve is Project and Marketing Director at Rober Industrieroboter GmbH, 59174 Kamen