Automation plays an important role in modern industrial environments. Robots can handle large and heavy components and speed up processes, but there are instances where personnel still need to access the areas where they operate.

Unrestricted or unauthorised access exposes operators to crushing and impact hazards, potentially leading to severe or fatal injuries. To mitigate these hazards, safeguarding solutions like interlocked guards are essential. Operators should only enter the safeguarded space once the hazards have reached a safe state.

AIC has been using amGardpro interlocks from Fortress to control access to its robot machines for over a decade. Access to the cell is allowed only after the robot has reached a controlled stop. The process involves halting the robot’s activity after its cycle is complete and confirming the safety status before access is permitted. The interlock’s solenoid locking mechanism holds the movable guard in a locked state. When required, operators can request to enter, and once the robot is in a safe state, the interlock is unlocked, allowing access to the cell.

The use of network-enabled solutions that can communicate with PROFINET and EtherNet/IP protocols allows simplified wiring, better diagnostics, and faster commissioning, all without compromising on the robustness required in steel plant environments.

Interlocks from Fortress also provide the possibility to include additional features, such as pushbuttons, emergency stops, and escape releases to allow operators to exit in case they inadvertently become trapped inside. With the help of Fortress, AIC now safeguards multiple robot applications installed across the world.

Meeting the safety needs of an evolving industry

As automation utilising robots becomes more advanced and widespread, there is a need for robust and flexible solutions to help keep operators safe. Through the adoption of networked interlocks from Fortress, it is possible to achieve improved safety, faster commissioning, and simplified maintenance.

These solutions show how advanced access control technology can meet the growing safety demands of heavy industries, protecting operators without compromising productivity.

The FRANK industrial access control software allows the management of permissions for machine control or access. Designed to work with amGardpro network-enabled interlocks and control pods, FRANK is compatible with existing RFID cards used on site, and logs interaction events such date, time, and frequency. These data insights can help support efficiency and productivity analysis, identify irregularities, and optimise processes.

Linking training records to access permissions

FRANK was implemented at the direct fire section of the main furnace. Since personnel can be exposed to dangerous gases, a mandatory gas awareness training is needed to be authorised in the area.

The access system previously in place did not differentiate between personnel with up-to-date or expired gas awareness training. The customer decided to adopt the FRANK system as it can link the access permissions to the training status. In this way, only employees with the right permissions and up-to-date training are allowed access to the gas hazard area.

Enhancing access control to the drossing robot area

FRANK was also used in the area safeguarding the drossing robot by the pool pit, which is where the heated steel strip enters the zinc bath. In the past, access was managed manually via a whiteboard system where personnel would sign in and out. However, this approach did not track who accessed the area and relied on people filling in the board correctly.

As well as ensuring personnel is authorised to be there, the FRANK software also provides a live update status on who is in the pot area, with interaction data displayed in real time in the control room.

Whilst initially implemented in two sections (the furnace and the pool pit), there are plans to expand the use of FRANK to other parts of the site, continuing to improve safety and operational efficiency across the facility.

Main advantages of FRANK

Several factors influenced the decision to adopt FRANK from Fortress Safety, including:

• Improved procedures: This solution offers better access control compared to previous protocols
• Real-time data availability: The ability to log and display interaction data in real time allows teams in the control room to monitor activities and take immediate action if needed
• Scalability: FRANK can easily be expanded to additional areas as needed
• Compatibility: The system works with the existing RFID cards already used on site, simplifying integration

In this specific case, the integration of training and access permissions with FRANK prevents unauthorised access, making sure that only authorised personnel with up-to-date training records are granted permissions and allowed access to certain areas. In addition, FRANK offers valuable insights through its data logs that help analyse user interactions and optimise access control processes.

This system requires no compressed air and complements the current generation of pneumatically-controlled magnetic grippers. The end-of-arm tool can be attached to robots and manipulators and holds a steel sheet or other product once gripped firmly in place, even during pick and place operations.

The energy-efficient magnet system has a bi-stable design, ensuring process safety even in case of power failure, an emergency stop or malfunction. With its plug-and-play design, the safe E-gripper requires little energy and eliminates the need for costly compressed air; something that the current generation of magnetic grippers do need. The gripper is mechatronically constructed and contains no moving parts. It is wear-resistant and has a long service life of more than ten million cycles.

Intelligent end-of-arm tool

The electrically switchable magnetic gripper was developed from market demand. Users do not always have compressed air available and want a safe and reliable system for automation processes. The magnetic gripper is equipped with a complete set of sensors, including inductive sensors for detecting product presence, as well as Hall sensors for signalling the on/off position.

If the workpiece is lost due to a collision or for any other reason, the PLC receives a real-time notification, so the line controller can react accordingly and the production process does not experience any serious disruption. Moreover, the E-Gripper is equipped with all-round visible LED lighting that indicates the status of the system with colours and light signals. This is particularly convenient for operators.

High productivity and long lifetime

The E-Gripper has a switching time of 350 m/sec, resulting in fast cycle times. The magnetic gripper holds products such as steel sheet firmly on a relatively small surface area and requires no changeover when changing product dimensions. The magnetic robotic gripper is a mechatronic product with no moving parts, resulting in no wear and tear. The only wear part is the friction ring, which is easily interchangeable and extends the life of the gripper.

The magnetic gripper has screw holes on the top and is easy to attach to a robotic arm as an end effector. Control is provided by internal electronics with integrated microprocessor and can be connected with only one cable for ‘power and logic’. The manual contains clear assembly instructions, making commissioning quick and easy.

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Its unique permanent lubrication provides a faster and more even distribution of the lubricant, even with short strokes. The complete contour of the patented multi-tooth guidance is equipped with grease pockets, which ensures a continuous supply of lubricant. This principle of the minimal quantity lubrication increases the already great life span of the SCHUNK best sellers.

“SCHUNK PGN-plus Permanent is a robust and perennial gripper, which reduces the operating costs, and offers a better performance as our current flagship PGN-plus,” said Dr. Markus Klaiber, CTO at SCHUNK. “It ensures an excellent repeat accuracy of 0.01mm, and ensures the implementation of particularly efficient systems.” It is equipped with an oval piston drive as its predecessor ensuring high forces in confined spaces.

The SCHUNK PGN-plus Permanent seamlessly integrates into the PGN-plus family. Nearly the whole range of possible automatic applications can be process-reliably controlled with the universal gripper – from machine/ system loading in the metal cutting industry, and in foundries to assembly applications in the automotive and electrical industry, up to delicate handling tasks in the medical and pharmaceutical industry.

The PGN-plus family has been successfully used in applications with high temperatures, pollutions, and aggressive media, as well as in clean rooms and explosive environments. On request, the modules are available with spring lock for mechanical gripping force maintenance, combined with compensation units for compensating angle errors, with force intensifier, or as a special precision version.

Moreover, a broad sensor program comprising of inductive proximity switches, magnetic switches and position sensors is available. Instead of many isolated applications, users reduce their internal coordination efforts by using the universal modular gripping system.

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Like those other high payload robots, the SMART NJ 650 is characterised by high stiffness, a compact, space-saving design and an optimised load capacity / payload relationship. Further, the SMART NJ 650 offers ISO 9283 repeatability from 0.15 mm.

Comau says the SMART NJ 650 is perfect for a host of industrial applications, including handling, spot welding of large body parts for the automotive sector, and the manipulation of heavy components for machine tending operations, as well as palletizing, deburring and polishing, packaging and machining in general, where the SMART NJ 650 elevated payload and reach will be important. The SMART NJ 650 can be also be deployed within the food and beverage industry, foundry operations or virtually any other industrial sector.

Arturo Baroncelli, segments management director at Comau, says: “The SMART NJ 650 allows us to expand and strengthen our presence in market segments that need to process heavy pieces. The SMART NJ 650 also enables us to respond to new production areas that increasingly require robots with a large payload capacity.”

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Ryobi Aluminium Casting has built up a significant population of Kawasaki robots over recent years with reliability being key to its continued investment. The Carrickfergus, Northern Ireland, based business is a global leader in specialist aluminium die castings.

Investment in Kawasaki robots began around 2008 with five ZX165U robots handling an automotive engine and transmission aluminium diecasting through the machining process. The 165kg payload robots pick a casting from a buffer conveyor to load and unload seven identical CNC machining centres that process a throughput of 300,000 units per year.

Ideally suited for machine loading applications, the Z Series robot has a horizontal reach of 2.65m and a payload of 165kg. This reach and capacity has proved to be the optimum for Ryobi’s throughput allowing it to source the same specification robot for all current and planned future requirements.

“To date we have 14 Kawasaki Z Series robots at Ryobi (UK),” says Neil Campbell, manufacturing manager, Ryobi. “Kawasaki was a trusted robot supplier to the integrator that installed the first system and we’ve not been disappointed. We never have any issues with the robots and if we have a power outage they just power back up again without problems.”

Over 45 operators at Ryobi receive training on the Kawasaki robots to ensure safety standards and confidence are maintained. This is managed efficiently in-house in conjunction with the local Northern Regional College (NRC) which has a staff member from its advanced engineering training department attending the Carrickfergus plant.

“Training is very important to us and with 45 people coming into contact with the automated cells it pays to have confident operators,” continues Neil. “We have an agreement with the local NRC who have had a lecturer in advanced engineering attend special training courses at Kawasaki Robotics in Warrington. Not only do we train to a high level of operational use and system programming but we are now able to focus on maintenance requirements.”

Recently installed Kawasaki robot systems were integrated by Evershed Robotics. In one system an automotive engine and transmission casting is handled through a trimming press and a shot blasting process while the stillages are handled and stacked when each one becomes empty. The completed casting then enters another cell where it is loaded into a Marposs leak tester by another Z Series robot.

Working with Heller the latest ERL system manages the handling of an engine and transmission casting through a washing process involving three machines and a vacuum dryer process. In each of the cells the reach of the robot relative to its small footprint allows the minimum amount of space to be taken up while providing a clean and un-complex solution. Additionally the 165kg payload allows double grippers to be used when required to speed up the load/unload process.

Each robot utilises the E-series controller with new higher speed processing, which enables application commands, both PC programmes and also Kawasaki’s K-Logic PLC programmes, to run at up to 18 times faster allowing cycle times to be reduced.

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The company already uses four KUKA robots with three models deployed on its series of 750 tonne automated diecasting machines while the other is used to saw and rout a variety of parts in a separate finishing operation. A decision to make a further investment in automation was an important part of its ambitious expansion plans, which were commenced in 2009 at a time when many firms were streamlining their operations in the wake of the recession.

Buoyed by new contracts and the backing of its bank and regional business development agencies, JH Lavender embarked on the largest-ever single investment project in its 94-year history with the creation of the new diecasting hall. The purchase of the new 1600t cell also means it is now one of only 4 aluminium diecasters in the UK with machines in this high tonnage range.

Diecasting machine maker Colosio, who commissioned and installed the new 1600t cell, chose a KUKA KR150 foundry robot as it is specifically designed for challenging work places. It is not only triple coated in heat-reflecting paint, but also has a heat-resistant inline wrist.

The robot performs a number of tasks once it has extracted the component from the diecasting machine. It lifts the part to a checking station where a set of 6 proximity sensors verify it is in tact and then chills the component by immersing it in a tank of water. The final task involves depositing the component on to a chute where it is collected by an operator who trims off any excess aluminium in a hydraulic press.

“Automation is crucial and the use of robots means we not only achieve optimum process control, but also consistent repeatability. KUKA robots are very robust and flexible, making them well-suited to working in a foundry environment,” commented Anthony Evans, JH Lavender’s business development manager.

In response to rising demand for its services from customers in the automotive and construction machine industries in the UK, Europe and the Americas, the company is already planning to automate a number of other diecasting machines in the near future.

“JH Lavender’s commitment to investing in automation demonstrates how businesses can transform a range of production processes and gain significant competitive advantages,” said Richard Goodwin, one of KUKA’s UK robot sales specialists.

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Lowering manufacturing costs by reducing scrap was an important objective for Newby who turned to Halesowen-based robot supplier KUKA and system integrator Geku to develop a compact automated solution for the challenging application.

Previously, the task was performed manually using pedestal drills but it was often a laborious method as many of the cores are not only complex shapes, but also require accurate venting so that gases produced in the 1500°C casting operation are expelled outside of the moulds. Under the new system, an operator loads a core into a jig, which is then fed into the cell on a shuttle table where it is picked up by the 16Kg payload KUKA robot. The robot then manoeuvres the jig in a series of positions over a bespoke drilling station depending on the number of holes to be drilled. When the operation is complete, the robot returns the jig to the shuttle table for unloading.

Since the cell has been installed, Newby has achieved a 40 per cent improvement in efficiency and expanded its capabilities by using the robotic solution to drill holes in a range of very small diameter cores, which was not possible under the previous method. “We’re very impressed with the results achieved by the robot which performs effectively and quickly. KUKA gave us all the help we needed and provided the right robot at the right price,” commented Steve Smith, Newby’s technical director.

Technical management trainee Adam Talbot, 21, who undertook a KUKA training course to learn how to program and operate the robot, praised the flexibility of the system as it “can handle a large number of jobs one after the other.”

As well as planning to invest in more automation in the future, Newby is also committed to providing high levels of training for its staff. Adam is being sponsored to study for a foundation degree in casting technology as part of a flexible learning scheme run by Bradford University and the Institute of Cast Metals Engineers. He joined the company in 2004 as an apprentice patternmaker and holds NVQ and BTEC qualifications in engineering.

“We want to plan for the future not only in terms of investment in equipment, but also in our management structure. We want to encourage a new generation to work in the industry,” said Steve Smith.

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Alongside the new developments in spring rod modules, there are also new special protective jackets now available. They protect the energy chain from liquid metal splashes or other materials. These are important in hot conditions such as in foundries, or for paint or sealing applications. The protective jackets are pulled over the energy chain and held by a Velcro fastener or elastic, thus ensuring the chain’s long service life.

Igus has developed the energy chain E4.1 for safe energy supply on the seventh axis. It allows high flexibility and robustness in all applications. Assembly times can be reduced by up to 80 percent thanks to improved opening and separating bridges. A quick-locking feature ensures little force is needed for opening and closing, even for very fully loaded chains. Special design, including the “tongue and groove” link joint improves the self-supporting length by more than 20 percent. The “tongue and groove” joint ensures very high rigidity even with strong lateral forces.

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The low profile dress pack module can be mounted directly to the existing fastening points on the robot. The moving end of energy chain is attached to the sixth axis with a mounting bracket. This dress pack system allows general movements, so no specific programming is required. Thanks to its compact design, the dress pack system can even be used if there is a valve cluster or distributor box on the third axis.

In addition, Igus also has new protective jackets available for the dress pack. These protect the dress pack from liquid metal splashes or other materials. This is important in hot conditions such as foundries, or for paint or sealing applications. The dress pack protective jackets are pulled over the energy chain, and held in place by a velcro fastener or elastic, ensuring the dress pack chain’s long service life.

Finally, Igus has also developed the E4.1 energy chain dress pack for safe supply on the seventh axis. It allows high flexibility and robustness in all robot dress pack applications. Assembly times for the dress pack can be reduced by up to 80 percent thanks to improved opening and separating bridges. A quick-locking feature ensures little force is required for opening and closing the dress pack chain, even for very fully loaded chains. Special design, including the ‘tongue and groove’ link joint ensures very high rigidity for the dress pack even with strong lateral forces.

Visit the Igus website for more information on the Triflex RS dress pack.

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