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FEATURE ROBOTICS & MOTION CONTROL UNCAGING YOUR ROBOT


Collaborative robots - or ‘cobots’ - are bringing the fences down in manufacturing and production facilities all over the world. Unlike early industrial robots that had to be isolated behind a protective cage, this new wave of robots comes equipped with sensors, vision and, in most cases, plenty of programmed self-control, enabling people and robots to work safely side-by-side. FANUC has recently launched a collaborative robot with an impressive payload capacity of up to 35kg


C


ompared to its yellow cousins, the Kermit-green FANUC CR-35iA is a


totally cage-free species of robot. Designed for tasks such as heavy workpiece transfer and parts assembly, robot and human operator can work collaboratively alongside each other without a safety fence. A dexterous six- axis arm with a reach of 1.813 metres, the CR-35iA also has a gentler side, including a soft green surface to reduce impact force and prevent a human operator being pinched. Certified to meet the requirements of international standard ISO 10218-1, if it comes in contact with a human co-worker or any object with a certain force, it stops or retracts immediately. In Japan, the robot has demonstrated its unique higher payload credentials, lifting and putting down a wheel.


Thanks to the success of the 35kg


payload collaborative robot, FANUC will shortly introduce another collaborative robot to its range - the CR-7iA with a payload of 7kg with mechanics corresponding to that of the company's LR Mate-series. This newest development represents a


significant leap in addressing robotic safety hazards. Although it doesn’t eliminate the need for comprehensive workplace risk assessments, the increased adoption of peripheral safety devices is enabling robots and humans to work in close proximity of each other, eradicating the fear of interrupting production or worse, causing an accident.


EMBEDDING GREATER CONTROL “Until recently, the mindset of most people was if you have a robotic hazard you banish humans from the robot working area with a physical guarding solution,” highlights Steve Capon, technical manager at FANUC UK. “That thought process for many is changing thanks to rapid


34 MAY 2016 | AUTOMATION


Collaborative robots are bringing the fences down in manufacturing and production facilities all over the world


advancements in sophisticated software control technology and integrated safety.” This now means that you can impose set


limits on how fast your robot works and the operational areas it can and can’t enter, programme your robot to slow down as it approaches a hazard rather than coming to an abrupt standstill, and even introduce presence-sensing detection. Above all, the newest robotic software


Steve Capon, technical manager at FANUC UK


is enabling manufacturers to think more creatively around how automation equipment is deployed and how companies can boost production efficiencies whilst also saving space in valuable commercial real estate. “Safety risks vary depending on the selected robot and application,” emphasises Capon. “One of the key advantages of being able to embed more of the safety- related functions into the robot controller is you can design out the various safety hazards whilst also eliminating the need for external fixtures or mechanical devices to supply this functionality.”


SETTING YOUR SAFE LIMITS In addition to meeting the safety requirements for electronic control systems, DCS Speed and Position Check offers significant benefits to applications where the travel of the robot needs to be restricted due to floor space or process limits that are less than the full reach of the robot. Restricting the robot motion in Cartesian space means the robot can be restrained to exactly the designated safe area in which it works; something that is not possible with systems that limit robot motion externally using limit switches. What’s more, this software works across the whole robot model, not just a single point. For example, ‘Position Check’ can identify multiple areas of the robot, including any attached end


effectors. The safe zones around the robot arm and its end effector can be modelled within the software, using geometric shapes of up to eight vertical lines each. These areas can be adapted – enabled and disabled to change the areas that the robot is not allowed to enter – depending on the task it is undertaking and the changing conditions within the defined area. “This is a useful feature for applications that require an operator to load parts into a fixture, for example,” says Capon. “An operator can safely walk into the area because the robot will stop the task it is performing. And when the operator leaves the defined area, the robot is able to continue with its task.” The DCS ‘Speed Check’ functionality


makes it possible to define the maximum speed that the robot can travel during normal operation. Speed can also be changed in reaction to a defined event, in addition to ensuring that the robot holds a position when necessary. This can be used for zero speed monitoring, explains Capon: “Often, there are rotary fixtures within a cell which must not move while the operator is undertaking a loading procedure. The DCS Speed Check functionality allows the speed of the fixture to be monitored, and ensures it remains motionless when required.” Ultimately, the onus on safety still rests


with humans. Even with all these technology advances and comprehensive workforce training you can’t risk becoming risk complacent. Every intentional and unintentional scenario when interacting with robots should be factored in when conducting regular risk assessments. With safety, getting it mostly right isn’t an option!


FANUC UK www.fanuc.eu /AUTOMATION T: 02476 518449


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