Robot applications supporting every industrial sector were also exhibited including: wafer transfer robots in the semiconductor industry; small painting robots that contribute to carbon neutrality; automation for the automotive sector which responds to changing models and volumes; hinotori, Japan’s first and most advanced robot system for robot assisted surgery; and Vambo, an automated devanning robot system for use in logistics sites.

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The joint venture brings together two companies with like-minded desire to challenge the current understanding of cobots in industry – entering a new era of collaborative automation.

The CL Series offers the best of both worlds, with full-on industrial scale performance and speed paired with maximum protection and all advantages of collaborative robotics. Combined with an intuitive user interface, the CL Series makes automating production lines easy.

With payloads and reaches of 3kg/590mm, 5kg/800mm, 8kg/1300mm and 10 kg/1000mm, the four models of the CL Series offer the perfect solution for every scenario. Free mounting orientations, extremely small footprints and IP66 classification provide additional flexibility – for all models. Its proprietary safety architecture and many features for safety positions, speed, torque, zones, limits and collision detection allow the CL Series cobots to operate alongside human workers.

The CL Series brings together speed of 200°/s, and repeatability of ± 0.02 mm for all models. The collaborative robot line is said to be the perfect choice for automating simple and repetitive tasks – effectively saving costs and maximising revenue.

Designed and made in Germany, the CL Series offers excellent performance through high-quality components, such as the integrated 24-bit encoders, which are among the highest-resolution on the market, and an extremely light-weight yet reliable construction. Thanks to its compact and robust design and IP66 rating, the CL Series can be used in all kinds of harsh environments that may not be suitable for other collaborative robots.

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Since the 1880s Ernst Hinrichs Dental from Goslar in the German Harz Mountains has been developing and manufacturing the first dental impression and model plasters worldwide. From the very start, the company has exclusively manufactured products based on high-quality natural and synthetic raw materials from the food industry, without the addition of allergenic substances.

Constant demand for these products developed led to expansion for the company, and over the next years, the product portfolio, sales and the company itself grew steadily. Today, Ernst Hinrichs Dental supplies dental wholesalers worldwide and is the international market leader in this industry.

A need for faster delivery to customers, more flexibility, relieving employees and increasing production rates made automation of the packaging plant for dental plasters necessary. Aside from the palletising of the final dental plaster product, the entire packaging and palletising process needed to be fitted to the product.

Kawasaki system partner Wehling Anlagen- und Maschinenbau (plant construction and mechanical engineering) from the German town of Oschersleben constructed, planned and implemented this demanding project – combined with the challenge of developing a gripping tool which could fulfil three tasks simultaneously without having to perform a time-consuming switch of tools in-between.

For this purpose, a multi-function gripping tool was developed and constructed, allowing it to grip bags of varying sizes, bring them into the right form and position them in the finished boxes. The quality of the raw materials not only determines the quality of the final product, but also of the packaging process itself. The entire filling and packaging facility consists of a carton erector, a sagging plant, several conveyor systems, a case sealer and a Kawasaki ZX130S palletising robot.

Due to the required flexibility of the plant, several products can be processed at the same time – with a minor variation in performance depending on the product category and the product itself. “Working with our client has been an excellent experience and the constant exchange regarding constructive ideas and development has been a major factor in successfully implementing the project,” says Matthias Wehling of Wehling Anlagen- und Maschinenbau.

Special Requirements

The physical properties of the dental plaster determine the choice of raw materials, the production as well as the packaging and palletising machines. After the dental plaster coming from the sagging plant has been packaged and sealed in 20 kg bags, a Kawasaki ZX130S robot grasps those bags using a multi-function gripping tool and positions them in a box produced by a carton erector.

In order to improve the positioning of the bags into the cartons and to avoid pendulum movement which might complicate filling the boxes, the bag is placed into the box along a sliding plate. The Kawasaki ZX130S uses a kind of masher, which compresses the bags in an additional step, to fit the dental plaster bags to the cartons so they can be sealed properly.

Due to the automation, shift operation could be reduced: while a three-shift operation was used before the automation, today a two-shift operation has been implemented. With an output of around 120 boxes per hour and 2,000 boxes per day, the plant packages around 40,000 kg dental plaster each day – and has been running smoothly for three years.

Handling and operating the robot is very easy and the employees’ satisfaction is very high. “The robot allowed us to increase production significantly and relieve our employees from exhausting physical labour,” says Stefan Schuetze, head of procurement at Ernst Hinrichs Dental, who is responsible for the entire production process.

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The loading robot is suspended from a gantry structure, leaving the floor near the machine free. The robot picks the workpieces to be machined from a grid table and places the machined workpieces back on the table.

The robot is equipped with a double gripper so that the workpiece is quickly changed in the machine clamp. Access to the robot cell is secured on three sides by a light curtain with two deflection mirrors, making access easy and safe.

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Order your morning latte macchiato conveniently via app from the bus, quickly scan the QR code and let the robot barista serve it fresh – MyAppCafé makes it possible. The 160 variants of coffee specialties – including espresso doppio, cappuccino, chocciato or latte – can of course also be ordered directly on the touchscreen.

The idea came to Karlsruhe-based MyAppCafé founder Michael Stille during a “Tatort” episode in which a catering robot played a central role. First conversations quickly began. A similar solution was already on the market in the USA – but without interest for the European market. Together with two other Karlsruhe companies, IBS and Rothweiler Feinwerkmechanik, Stille developed its own solution.

The decisive goal during development was cost-effectiveness: each franchisee only needs to spend a maximum of one hour a day refilling and waiting, the rest is fully automated. MyAppCafé only needs to be refilled after around 650 issues.

“Almost no personnel is required, a maximum of one hour of working time for refilling and cleaning must be scheduled after 650 issues,” says Stille. “By comparison, four employees would be needed to provide the same service. With our robot Barista, you are in the profit zone much faster.”

The integrated fully automatic cleaning systems combine the highest hygiene standards with minimum effort. A robot is the heart of the cell: the prototype as well as all further cells were built based on the Kawasaki Robotics RS005L.

With a maximum payload of 5 kg and a maximum reach of 903 mm, the RS005L is part of the universal R series for small to medium payloads, suitable for assembly, material handling, machine tending and many other applications. Its special design enables the high-speed robot to have a longer reach and an extended working range.

In addition to the technical aspects, the RS005L convinced Stille with its appearance, which fitted well into the design of the cell: “We wanted to have a real industrial robot inside, not a ‘toy’. And Kawasaki was very accommodating to us as a partner and through the quality of the robots.”

For the first MyAppCafé cell, the Postgalerie shopping centre in Karlsruhe was quickly found as an optimal location, quickly followed by other locations and with more to follow.

In operation, after receiving an order for the desired coffee specialty via app or touch screen, the Kawasaki robot takes a cup and transports it to one of the two high-end coffee machines as well as to two syrup stations and a specially developed milk system, as required. It then moves the finished coffee to one of the dispensing stations where it can be removed for immediate enjoyment.

The robot can prepare and serve up to 120 coffees per hour. And the hot drinks can be decorated with an individual text message or picture on the milk foam using a food printer, at no extra cost. Customers can even upload their own photos via app and have them displayed on a fresh cappuccino.

“Our customers can be as creative as they like,” says Stille. “They can upload a vacation selfie directly from Milan and order the printed coffee in Karlsruhe for their return.”

The robot barista never gets tired: MyAppCafé is active 24 hours a day, seven days a week – without waiting or queuing.

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With its double-walled underground storage tanks, German company Haase Group has been a market leader in the tank industry for more than 50 years and relies on a unique combination of traditional manual work and modern automation technology.

Since its start in 1999, Haase has recorded strong growth. Managing director Thomas Falkenbach says: “We looked for and found a market niche. This has enabled us to position ourselves successfully as a pioneer in the field of tanks – regarding material, quality and flexibility.”

Haase was an early adopter of robotics, installing its first robot in 1991. This upgrade brought a noticeable relief for the company, so it continued down the path of automation. As time went on and the robots grew older, maintenance and servicing became increasingly difficult. When it was no longer possible to guarantee reliable procurement of spare parts in the long term, they knew it was time to upgrade.

A central challenge in the construction and operation of the plant was the considerable amount of dirt and dust produced during processing. It needed a robot arm suitable for a dusty environment and a controller that didn’t require constant cleaning.

Haase installed the Kawasaki ZT130S robot to spray glass fibre reinforced plastic (GRP) onto the double-walled cellar and underground storage tanks during the finishing process. The robot is shelf-mounted next to a turntable where the parts are fixed, making it easy to apply an even coat of GRP.

The ZT130S robot provides the payload (130kg) and a horizontal/vertical reach (3,230 mm/4,571 mm) needed for this application. However, its wide working range and high precision capabilities make it perfect for the spraying process specifically. The robot is able to process both single or multiple lids and bases in series, offering maximum flexibility and greatly increased efficiency.

Due to the success of the ZT130S, Haase added a Kawasaki BX100L robot to the production site, which is also used to apply resin and glass fibres to a mould. It also added another ZT130L for working lids and bottoms with the automatic tool change system. This system provides them the flexibility they need to manufacture approximately 100 different tank types as needed.

Jürgen Krell, technical director at Haase, decided to go with Kawasaki Robotics after interacting with the company at the Automatica trade show. “For us, the attractive price, the robust design and the specific but precisely fitting [specifications] of the robot were the deciding factors. With a proven Kawasaki partner in the neighbouring town, the available service was also excellent for us. And the technical support provided by Kawasaki itself has quickly proven to be particularly reliable and flexible.”

A suction system was made to ensure continuous and effective extraction of dirt during the finishing process, which removed 60% of airborne dirt. The Z series robots run on Kawasaki’s E series controller, which only needs to be cleaned once a week for optimal performance.

Haase also developed and built a special tool change station so the robot can efficiently switch between four different tools needed for finishing. The shelf-mounted ZT130L robot is not dependent on special tools – it uses commercially available machines such as a milling tool to prepare the manhole in the tank and an angle grinder to prepare the tank surface for lamination and further processing. The robot also uses two saws enable precise cutting of the workpiece and grinding of the outside of the tank and a suction attachment for a thorough cleaning of the lids and bases.

A light barrier effectively protects the working area of the robot in combination with the Kawasaki Cubic-S safety system. Cubic-S ensures that robots and workers can work together safely and without hesitation. The software enables the installation of particularly space-saving applications and security areas without complex external security measures. Cubic-S combines eight safety functions – including the individual definition and precise limitation of the available working space. The robot cannot exceed the specified working range limits at any time.

For this safety system to work, the individual axes of the robot are electronically monitored. Predefined axis values from the limits of possible movements. If a predefined speed is exceeded, previously stopped axes are moved or tools leave their intended orientation, Cubic-S automatically switches off the robot.

Looking at the results of the robot installations, Kress says: “We more than doubled our output compared to 2011. The three Kawasaki robots play an important role in this.”

While the oil tanks are only sold to German customers, other products such as heat accumulators as well as oil and grease separators are also in demand on the international market – and are exported to Scandinavia, Italy, Dubai, Southeast Asia and the USA, among others. The Swiss Federal Railways, for example, are currently completely converting their light liquid separators to Haase tanks. “The successful automation and use of robots create the basis for our further growth. This enables us to meet the growing demand in a targeted manner,” adds Falkenbach.

He draws a positive conclusion from recent years. “The use of Kawasaki robots has quickly paid off for us and offers us full flexibility in the long term. Our team is always working on further optimising the close cooperation between robots, tools, extraction system and turntables.”

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BBI had been plagued by frequent machine breakdowns on their manually run COS machine, which they had for over 25 years. The antiquated machine was causing costly delays in production – BBI was experiencing four to five hours of downtime a week.

The process of manually stacking battery plates and loading plates into jars generated more airborne lead dust, which posed a greater risk for exposure than if the process was automated. The older machine also required employees to lift heavier loads, resulting in a greater risk of injury. For BBI, it was important to see the positive impact of automation reflected in their work environment – not just on their bottom line.

In order to properly create its lead-acid batteries, BBI had to install a workhorse precise enough to consistently align 300 lbs of battery plates up to 500 times per day. The robot also needed to be able to brush off the end connectors on the batteries, dip them into molten lead, and package them in a plastic jar, among other tasks. In order to accomplish this diverse list of detailed tasks, BBI needed a versatile robot.

One of the manufacturer’s primary goals for automation was to increase its overall plant efficiency and increase its battery cell production numbers. The old COS process it targeted for automation required nine or ten employees to operate, and it was looking to decrease that number. BBI also recognised that its employees could be more useful in other areas of the manufacturing plant.

Almost immediately, BBI saw the advantages of its newly installed Kawasaki robot reflected in the quality of their end product. The number of labourers needed to man this process has gone down from seven to five.

The robot steps in after the battery plates have been manually slid onto the conveyor to align the plates and ensure they are even and flush. During this new process, operators no longer have to lift the plates from the ground – they move of the plates laterally onto a conveyor which is a more ergonomically friendly move.

From here, the robot picks up the plates and runs them over a large bristle brush to remove any lingering debris from the end connectors, called lugs. Next, the robot runs the product through a flux process. The lugs are then dipped into tin, and dipped again into molten lead.  Last comes the case out process, where the robot places the battery plates into their plastic casing.

Although Kawasaki’s ZX300S robots are capable of carrying payloads of up to 300 kg, they combine a long reach arm with a minimal amount of dead space for a wide work envelope. They also have a high repeatability of ±0.3 mm, making them ideal for applications that require precision and heavy lifting. When combined, these features created the perfect solution for BBI’s setup, which required the robot to be able to reach multiple machines at varying heights.

Kawasaki’s newer large payload robots, the B and CX series, large have even higher repeatability, ranging from ±0.06 to ±0.08 mm. Both series have a hollow arm structure, which allows for internal dressing of the robot. This feature simplifies installation by reducing the amount of time needed for manufacturing line builds and digital engineering, and minimises the risk of interference with other robots or peripheral equipment.

For BBI, working with their new robot has been smooth sailing. “The robotics part of this process was very easy. Installing the robot was no problem at all, it was very simple, and learning to work with it wasn’t too complex,” BBI’s assistant manager said.

BBI chose MAC Engineering because the high quality and performance of MAC’s battery-making equipment has made it one of the world’s most popular integrators for this type of application. After supplying more than 4,500 machines in over 80 countries to date, MAC is continually looking to the future to develop new products.

Since replacing their old, breakdown-prone COS machine, BBI has seen a better, more consistent product quality using fewer man hours, and created a significantly safer work environment. The employees who used to operate their old machine are now working in the battery assembly department – allowing BBI to put more man hours toward the final stages of battery assembly and ultimately improving the overall quality of its batteries. Once all of the integration is complete, it will be able to increase production from 400 to 1,000 battery cells per day – more than double the output it saw prior to automation.

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With more than 60 years of experience, Ossenberg has become the market leader for walking aids – developing, manufacturing, and distributing crutches, light metal canes and orthopedic aids for global retailers. In order to keep up with the fast company growth and the increased demand for its products, Ossenberg’s management team decided to automate their primary metal processing application.

In addition to higher production flexibility and easy handling of several pipe lengths, precision was at the top of Ossenberg’s priority list. Instead of drilling or punching the height-adjustment holes into the pipe as has been done previously, the holes were going to be milled. For pipe processing, a positional repeatability 0.1 mm and a drilling accuracy of +0.05 mm is essential. Furthermore, the pipes should be deburred from the inside and the outside at the same time.

Ossenberg produces its articles on an order-by-order basis and foregoes extensive warehousing in favour of agile, demand-oriented production. Therefore, great speed, short cycle times and fast shipping are decisive factors. Only eight minutes pass from accepting an order to starting production, and the final shipment arrives at its destination less than 36 hours after the order is placed.

The standard Ossenberg walking aids are available in 850 variants, including multiple colours, different materials and adaptable sizes and load capacities. This enormous product variance requires a high degree of flexibility from their robotic system.

During a visit to an automotive supplier, Ossenberg managing director Carsten Diekmann experienced the efficiency and user friendliness of Kawasaki robots firsthand. “Kawasaki Robotics has a very good reputation and many companies appreciate not only the modern technology, but also the flexibility, the local service and the special focus on small to mid-sized companies,” Diekmann explains. “While other manufacturers were not able or willing to fit our particular needs, the Kawasaki team was able to consult us comprehensively and conduct preliminary tests.”

Now at the Ossenberg production facility, ositioned centrally inside a 20’ by 30’ cell, a Kawasaki RS020N handles the pipe processing. After the pipes in their raw form are supplied through an external shaft, cut to the right length, and deburred, the welding seam is turned to the right side to guarantee a precise alignment. After this step is complete, the robot moves the pipes towards a fixture, where an additional RS050N robot equipped with milling tools will mill the precisely positioned height-adjustment holes into the pipes from both sides.

During the final step, it is possible to automatically attach the spring-operated push buttons for height adjustment. Depending on the product requirements, it is also possible to recognise bending angles within the outer pipe component. This allows a highly flexible and economic production process for different components and allows Ossenberg to easily manufacture walking aids in multiple variants and shapes. The entire pipe processing plant is constructed in a modular fashion and controlled using one interface, which ensures a simplified, flexible, product-specific operation.

Managing director Dietmar Fark worked closely with the Kawasaki engineers throughout the process to ensure streamlined operation and quick start-up. This way, the plant was up and running quickly, and Ossenberg experienced increased production volume and efficiency almost instantly. While processing a pipe took 5.5 minutes before, now the system can process six pipes in 50 seconds.

Within a short time Ossenberg was able to increase their entire production volume to more than one million items per year. Today more than 10,000 walking aids – as opposed to 100 ten years ago – and 3,000 to 4,000 handles are manufactured daily as part of a three-shift operation. By automating this process, production stability has increased significantly and offers long-term job security to the employees in their facility.

Over the next few years, Ossenberg plans to further develop their facility and continue growing its production volume. As an example, Fark says: “The automation made possible by the Kawasaki robots increased our output exponentially. And there is still room for more: through specific process improvement we plan to decrease the time necessary for six pipes to 45 seconds.”

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In reality, there are many ways to embrace automation without starting from scratch, and the available resources make programming and maintaining a robot possible for all knowledge levels – including first-timers.

Baton, a manufacturer of AirStone faux stone veneers and siding, learned this first-hand when it installed its first robot with the help of Dakswan Automation. Once implemented, the Kawasaki RS080N general purpose robot helped Baton cut down production time and significantly reduce waste, with minimal changes made to their existing production line and tooling.

Prior to automation, in order to produce AirStone, four painters sprayed liquid cement onto moulds as they approached on a conveyor. Each painter used a different amount of material, resulting in inconsistent products and over-use of materials. Further, workers were required to wear respirator masks while spraying the moulds to remain safe and minimise exposure to liquid cement particles while on the job.

For manufacturers whose products are constructed in harsh environments, it can be difficult to retain employees, and that task is even more challenging during an industry-wide labour shortage. This lack of consistency can lead to low production, and is a primary reason why Baton decided to automate their spraying process.

Minimal process changes only

The RS080N was Baton’s first robot, so the manufacturer was hesitant due to concerns that this new equipment would be disruptive to the process it had developed over the past five years. Dakswan needed to design a customised solution that aligned with its customer’s manual process

“It took years to develop our spray system that applies colour into our product, and the manual gun we use works well for a number of reasons. It would have been hard to replace,” said Tom Scanlan, owner and president of Baton.

The robot is positioned in the same place as the workers were previously. When the parts arrive in front of the robot on a conveyor, the robot is programmed to paint at the same speed as the human workers before it, but the robot’s ability to work all day without breaks saves average of 2.5 hours of downtime each week.

Choosing a robot from Kawasaki’s line of high-performance, general purpose robots, as opposed to paint robots, was a purposeful choice by the integrator, who picked this specific model due to its long reach capabilities. The RS080N robot’s extended reach (2,100 mm) made it perfect for Baton’s application, which required the robot to spray a large area from one fixed location.

Kawasaki’s R series robots are designed to be effective in workspaces large and small. In addition to their extended reach, the large rotation range of the R series’ axes translates to a larger usable work area with minimal dead space, so multiple robots can be installed in high-density applications without impeding performance. The slim arm design of the R series requires very little floor space, making them a good option for tight spaces, like Baton’s paint booth.

Kawasaki’s option for a built-in PLC, called K-Logic, was another key selling point for Dakswan Automation. K-Logic streamlines operations for the end user because all communication between the production line and the robot is done internally. K-Logic also kept costs down by eliminating the need for an external PLC, and minimising the amount of external cabling needed.

Same process, modernised

Because the RS080N robot isn’t designed for performing paint/spray applications, Dakswan designed a custom end-of-arm tool to hold the exact same paint system their customer was currently using. This allowed Baton to retrofit their current paint gun, utilise spare parts it had acquired over years of using this machine, and keep its end product consistent with what it had sold in the past.

Dakswan installed the robot in the same place the human workers stood during the manual process, which meant Baton could keep its existing machinery and equipment in the same location, and only small adjustments needed to accommodate the new robot.

Although Baton is technically a first-time robot user, the knowledge its maintenance staff acquired from the operations and programming training course they took at Kawasaki’s training centre has enabled them to keep their robot up and running smoothly entirely on their own. Additionally, they are able to reprogram the robot to test out different spraying patterns for new products.

After installing their RS080N robot to perform a ‘human unfriendly’ task, the benefits of automation showed themselves in multiple ways throughout the company. Baton saw a boost in production, so the workers who formerly sprayed the AirStone moulds were redeployed to the different areas of the company that don’t require exposure to harsh chemicals or protective gear.

“Since we hadn’t had any experience with robots, there was apprehension (around) the robot going down, how often that could happen – or if (the robot) was going to cause headaches with our manufacturing process,” said Scanlan. “But it’s been the opposite. It works every day – we don’t really have to do anything.”

From an operational standpoint, Scanlan uses the words “worry-free” to describe using the new Kawasaki robot – despite his initial concerns as a first-time robot user. “It was a very easy process to convert over from manual to robotic. Without a doubt, worth the investment,” he said. “It’s been such an apparent positive to our plant: the reduction of material costs, reduction of downtime — all of it. Using the robot is just kind of worry-free.”

For Baton, automation didn’t mean overhauling a proven process or experiencing stress from complex programming or unexpected shutdowns. The robot has improved Baton’s manufacturing process while creating a safer work environment for its employees. Dakswan Automation designed and implemented a cost-effective solution that utilised the machinery and tooling Baton had spent years adopting, making for a seamless transition and a robotic solution it is able to maintain entirely on its own.

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GS-MR is armed with more than 35 years of engineering excellence, with 16 years of global high-end machinery experience in the glass processing industry. “The only robots we use are from Kawasaki,” says GS-MR director Robert Owen. “The wide range of models available and their durability is matched by the technical competence of their sales and integration teams. That back-up and knowledge has always proved pivotal and has given us a significant advantage when we’re in project discussions with our customers.”

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