TPR provides smart solutions for robot drilling and inspection, designed to fit within a digital landscape. As part of the Innovate UK funded ADI Project (Automated Drilling and Inspection), TPR’s technology plays a key role in transferring robot programmes which have been created offline, to the real robot, and guiding the robot in space to become a true digital twin.

As part of the project, multiple robot tool changes are required prior to and following machining operations. To optimise the utilisation of the robot in this application, a robot tool changing system would be required. It would be essential however, that any tool changer system used would be able to not only deliver the different media and services required, but crucially provide consistent functionality, precision, and performance.

Stäubli worked closely with TPR on this project to specify the MPS 130 R20 robot tool changer and CombiTac connectors which connect the water, air, power, and data signals required for this aerospace project. The ability to obtain both the connector and tool changing technologies from a single source, as opposed to using hybrid technologies from different suppliers, is seen as a benefit as the manufacturing processes, materials, tolerances and ultimately product reliability and compatibility is guaranteed.

Stäubli’s MPS 130 R20 robot tool changer and CombiTac connectors are now at the heart of this innovative system, performing the tool changing operations between the inspection systems used to define datums prior to machining, the drilling technology used to produce and countersink the holes, and finally the laser scanning system for final process verification.

Roger Holden, director at TPR commented on the Stäubli solution: “The main benefit for us is when we disconnect and then re-connect the different tools, we don’t have to worry about the consistency or quality of the different services. We can take that for granted as we have full confidence in Stäubli’s solution.”

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The Stäubli Fluid Connectors stand at this year’s exhibition will feature a range of different products and technologies including energy connection, process automation, robotic tool changers, end-of-arm-tooling, quick mould change solutions and mould temperature control.

Of special interest to visitors to the Stäubli Fluid Connectors stand will be the latest in Magnetic Mould Clamping Technology – QMC123, the result of the recent strategic partnership between Stäubli and Mag Autoblok-Tecnomagnete.

The combined expertise of the two companies has taken the capabilities of magnetic clamping technology to a new level, with enhancements and improvements across a number of key areas. Also on show will be examples from the company’s comprehensive range of Automatic Robotic Tool Changers and End-Of-Arm-Tooling (EOAT).

With a heritage of collaborating with companies in the plastics industry for more than 60 years, Stäubli Fluid Connectors is recognised as having unrivalled expertise across all areas of the sector. Stäubli provides a comprehensive range of solutions that save time at every stage in the injection moulding process, increasing productivity, efficiencies, and profitability.

Businesses within sectors such as automotive, white goods, home appliances, packaging, IT, electronics, building construction and many more rely on the quality, performance, and reliability inherent in Stäubli’s product offering.

Stäubli’s stand can be found in Hall 4, Stand Number H32 where the company’s experts will be on hand throughout the show to offer advice on how Stäubli products and solutions can improve and enhance plastics manufacturing processes.

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Industrial robots have revolutionised manufacturing processes across many industry sectors through their flexibility and capability to adapt to numerous tasks. However, with increasing levels of flexibility being demanded by consumers across several different sectors, and shorter product lifespans, manufacturing processes today need to be even more agile to cater for this lower volume but higher mix scenario.

Key to maintaining the flexibility to meet these demands are a combination of automatic robot tool changing systems and a comprehensive selection of End-of-Arm-Tooling components, to allow manufacturers to quickly configure their robot systems to handle both current and future product variants and processes.

Automatic robot tool changers make it possible for the robot to quickly exchange tools, allowing the robot to perform different processes, or adapt to different product variants. With automatic changeovers taking just seconds, compared to many minutes for a manual changeover, the highest productivity levels can still be maintained even on short batch runs.

A further benefit of this technology is the ability to provide an agile response to changing customer demands, when compared to conventional and more dedicated production methods. The capability to respond quickly to new customer initiatives, not only satisfies immediate customer needs, but provides a competitive advantage by enhancing customer / supplier relationships.

Robot tool changing systems from Stäubli Fluid Connectors are designed for all robots and payloads regardless of manufacturer and robot type. The modular design of the MPS tool change systems cover the entire spectrum of potential applications, and all media and signal connections can be integrated with this comprehensive and versatile product range. These latest generation systems offer numerous different modules for the transmission of pneumatics, vacuum, signals, data transmission up to 10Gbit, PE protection and earthing, and RFID technology.

The MPS robot tool changing systems from Stäubli Fluid Connectors ensure a repeatable, precise, and stable connection between the robot and tool, even when high numbers of tool changing cycles are required. Stäubli also provides integrated solutions for the secure docking of the different robot tools. A range of docking stations are available to suit the different sizes of MPS tool changer.

End-of-arm-tooling solutions

The essential interface between the robot and the product is the End-of-Arm-Tooling. For the robot to be both effective and productive, it is essential that the End-of-Arm-Tooling is not only perfectly matched to the task at hand, but in applications where robot tool changers are being used, also completely compatible with them. The recent close cooperation with End-of-Arm-Tooling technology partner FIPA is reflected in the range of gripper, End-of-Arm-Tooling components, and systems now available from Stäubli Fluid Connectors.

A broad portfolio of highly flexible End-of-Arm-Tooling solutions is available for many different material handling applications and automated manufacturing processes.

Individual processes and applications require a solution that is precisely tailored to that task. Stäubli is able to apply their expertise to support customers in developing the perfect solution for their unique requirements, from initial CAD concepts, through the planning of the system, to delivery of all the components required for the application, including the necessary drawings and component descriptions. Alternatively, customers can opt for a complete fully assembled solution delivered to site and ready for integration.

High levels of durability and flexibility within End-of-Arm-Tooling solutions are essential attributes if a long-term return on investment and minimum total cost of ownership are to be achieved. Stäubli’s reputation for high-precision and high-quality products with a long service life ensures that these objectives are achieved.

Also, with a comprehensive array of individual profiles, union joints, mechanical grippers, vacuum cups, vacuum generators, electronics, and sensors, End-of-Arm-Tooling systems and solutions from Stäubli Fluid Connectors can be quickly and easily re-configured or retrofitted to cater for new product variants or processes.

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Stäubli Fluid Connectors has entered into a close partnership with Fipa for its end-of-arm-tooling. Fipa specialises in the development and manufacture of products in the area of vacuum and handling components as well as complete systems for handling processes.

Fipa’s flexible product system, and its corporate philosophy, are a perfect match for Stäubli Fluid Connectors, and its own modular product concept. Armed with this joint expertise, the partners intend to develop solutions for future-oriented manufacturing concepts.

Martin Bergmüller, project manager for end-of-arm-tooling at Stäubli Fluid Connectors, commented: “Fipa is the ideal partner: we have established a strong partnership that is characterised by high standards of quality and solution orientation on both sides. The cooperation combines the skills of both companies into a strong proposal consisting of global availability, broad applications knowledge and excellent technical expertise.”

Norbert Ermer, head of the robotic tool changer business at Stäubli in Bayreuth, said: “Stäubli Fluid Connectors is known for its expertise in automatic tool changers and is now expanding its range to include material handling components and systems. Stäubli Fluid Connectors offers all functions and technologies for this from a single source. And we support our customers comprehensively right up to the fully assembled handling solution.”

Both system developers and system operators will benefit from this partnership: the components supplied are ideally matched to each other. From Stäubli’s point of view, this not only reduces interface problems but also eliminates time-consuming coordination with various points of contact.

Solutions for all applications and robots

The automation of material handling processes requires expertise and precise planning. Stäubli Fluid Connectors relies on their many years of experience in the development of individual solutions and offers comprehensive support: as an established supplier of automatic robotic tool changer systems – and now also of material handling solutions – the company has the product portfolio and the expertise to offer solutions even for particularly complex handling processes.

From the analysis of the framework conditions and application requirements, to the concept and CAD planning of the system, through to the delivery of all components, Stäubli Fluid Connectors offers a complete service package. Also, upon request, the solutions can be delivered fully assembled.

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Five new sizes have now been launched to expand the existing MPS tool changer range, covering payload capacities from 15kg to 80kg, enabling Stäubli to offer a robotic tool change solution for virtually all robots and payloads. Key characteristics of the new compact range include repeat accuracy of ±1.5 µm and a wide variety of available transfer technologies.

Automatic tool changing systems can significantly increase the flexibility and productivity of a robot. Indeed, for many manufacturing processes and applications across a wide range of industry sectors, automatic tool change systems are the only way to address the specific and individual operations required.

All Stäubli robotic tool changing systems are based on a modular product concept, with three different and efficient ways for customers to obtain their ideal tool changing system. The MPS COMPLETE designation offers pre-configured complete systems ready for immediate use and available on short delivery times.

Stäubli’s MPS MODULAR option offers readily available and production ready solutions tailored to meet individual customer requirements. The third option is MPS CUSTOMIZED. These systems are designed around the pre-requisites of each unique application.

Integrated functionality and a wide range of modules

Feed-throughs for pneumatics or vacuum are already integrated into the locking units of the new systems. For customers considering future flexibility and functionality, there are numerous additional modules available for the transmission of pneumatics, vacuum, signals, data transmission up to 10Gbit/S, shielding, earthing, RFID tool coding and data storage. The ability to combine these different technologies and modules as required makes it possible to configure a solution for the widest possible range of applications.

The location of the transmission modules is also highly flexible, allowing users to position them as required to suit the individual robot’s cable package, and order them using a simple code. The robot mounted component of the MPS Tool Changer incorporates all of the services required to provide functionality for the various tools which may be used by the robot in production. On the tool change element, the only transmission modules required are those relating to the operation of specific tools. This makes it possible to use multiple individually configured tool elements with one robot mounted element, optimising customer return on investment.

Stäubli combines cross-shaped guide surfaces with a spring-loaded ball locking system to achieve interconnection between the robot and tool sides of the MPS system. This makes it possible for the system to maintain the highest levels of precision throughout its entire product lifecycle. The tools always return to their original insertion position with a repeat accuracy of ±1.5 µm. Status monitoring, which is available as an option, is integrated directly within the locking unit of the tool change system. This space-saving concept means that there is no overall height increase in the coupled tool changer, keeping the mass moment of inertia of the tools to the minimum possible, and therefore optimising the robot payload.

In keeping with the already established Stäubli tool changing systems, for robot payloads up to 1530 kg, the new systems for payloads up to 80 kg also attach directly to the ISO standard flange of every robot produced worldwide, without the need for an adapter. This drilling pattern is also the same on the tool side for ease of assembly.

Individually configured robotic tool changers are delivered to the customer fully assembled and ready for use. Thanks to the modular design of the systems, Stäubli’s MPS robotic tool changers can be adapted or expanded at any time for new applications.

A range of tool stands are available for all sizes to locate and store the individual tools being used by the robot. These are available as complete units, or as separate modules which can be mounted to standard profile section framework arrangements.

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Automatic tool changing systems can significantly increase the flexibility and productivity of a robot. Indeed, for many manufacturing processes and applications across a wide range of industry sectors, automatic tool change systems are the only way to address the specific and individual operations required.

All Stäubli robotic tool changing systems are based on a modular product concept, with three different and efficient ways for customers to obtain their ideal tool changing system. The MPS COMPLETE designation offers pre-configured complete systems ready for immediate use and available on short delivery times.

Stäubli’s MPS MODULAR option offers readily available and production ready solutions tailored to meet individual customer requirements. The third option is MPS CUSTOMIZED. These systems are designed around the pre-requisites of each unique application.

Integrated functionality and a wide range of modules

Feed-throughs for pneumatics or vacuum are already integrated into the locking units of the new systems. For customers considering future flexibility and functionality, there are numerous additional modules available for the transmission of pneumatics, vacuum, signals, data transmission up to 10Gbit/S, shielding, earthing, RFID tool coding and data storage. The ability to combine these different technologies and modules as required makes it possible to configure a solution for the widest possible range of applications.

The location of the transmission modules is also highly flexible, allowing users to position them as required to suit the individual robot’s cable package, and order them using a simple code. The robot mounted component of the MPS Tool Changer incorporates all of the services required to provide functionality for the various tools which may be used by the robot in production. On the tool change element, the only transmission modules required are those relating to the operation of specific tools. This makes it possible to use multiple individually configured tool elements with one robot mounted element, optimising customer return on investment.

Stäubli combines cross-shaped guide surfaces with a spring-loaded ball locking system to achieve interconnection between the robot and tool sides of the MPS system. This makes it possible for the system to maintain the highest levels of precision throughout its entire product lifecycle. The tools always return to their original insertion position with a repeat accuracy of ±1.5 µm. Status monitoring, which is available as an option, is integrated directly within the locking unit of the tool change system.  This space-saving concept means that there is no overall height increase in the coupled tool changer, keeping the mass moment of inertia of the tools to the minimum possible, and therefore optimising the robot payload.

In keeping with the already established Stäubli tool changing systems, for robot payloads up to 1530 kg, the new systems for payloads up to 80 kg also attach directly to the ISO standard flange of every robot produced worldwide, without the need for an adapter. This drilling pattern is also the same on the tool side for ease of assembly.

Individually configured robotic tool changers are delivered to the customer fully assembled and ready for use. Thanks to the modular design of the systems, Stäubli’s MPS robotic tool changers can be adapted or expanded at any time for new applications.

A range of tool stands are available for all sizes to locate and store the individual tools being used by the robot. These are available as complete units, or as separate modules which can be mounted to standard profile section framework arrangements.

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The completed range of tool changers covers all payload classes and is based on these three solution variants:

• MPS Complete
• MPS Modular
• MPS Customized

Allowing for the specific requirements of each industrial sector to be covered in a highly flexible manner, with the objective of building the ideal tool changer system for any application. Stӓubli’s MPS robot tool changer systems have always been based on a modular system that allows flexible adaptation to individual user requirements.

In order to guarantee maximum functional reliability of the changers, Stäubli is the only manufacturer worldwide that develops and manufactures the complete changers in-house. The locking mechanism, the media modules and the complete connection technology come from a single source. The advantage is that all components are produced under a consistent quality management system to the highest manufacturing quality with no dependence on third parties. The “all under one roof” approach means a compromise free design with all elements optimized to work in tandem.

MPS COMPLETE: Ready to use application solutions, MPS COMPLETE offers the quickest and simplest option. Stäubli has recognized the most common applications in the industry and designed pre-configured solutions. The advantage is that these solutions are readily available. Still offering flexibility as the transfer modules can be exchanged or upgraded at any time to reflex changing operating requirements.

MPS MODULAR: For applications where an individual configuration of the tool changers is required, MPS MODULAR is the ideal solution. The user can configure each tool changer to their individual application to meet specific requirements. The selection of suitable transfer modules is surprisingly easy despite the multitude of possibilities. The user can reposition the transfer modules at any time and, if necessary, adapt them to changing production technologies.

MPS CUSTOMIZED: For more complex applications, which cannot be optimized by implementing the previous solutions, Stäubli supplies specific assemblies via MPS CUSTOMIZED. Our MPS specialists adapt the base units on the robot and tool side to the requirements of the specific application. The result is a precise system that fully meets the defined specifications including material quality and safety specifications. In addition, optimized individual tool stands are available for integration into the production line.

Stäubli Fluid Connector Divisions range of tool changers provide an innovative three-way concept demonstrating how robotic tool changer systems enable robots to perform a multitude of different tasks, increasing their utilization and economic efficiency. It is important to note that all models meet the safety requirements conforming to safety category 3 Performance Level d.

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Demands on production lines and robot cells are continuously increasing in the automotive industry, in particular. This involves factors such as quality and flexibility, as well as energy efficiency, sustainability and productivity. Additional operations usually require additional robots; but with the facility to quickly and automatically change the tools on a robot arm, the need for a second or even third robot is eliminated, significantly reducing the capital investment required, improving payback and often reducing the overall cell footprint.

The use of automatic tool changers is an excellent way to achieve these goals. If robots are capable of independently changing grippers and tools, then more complex tasks can be set up. Automatic tool change systems enables robots to perform a wide-ranging tasks, which improves their deployment and, therefore, their efficiency. Additional benefits: With tool changers, the degree of automation and autonomy of robot lines can be significantly increased. Where there is the possibility for additional vehicle variants to be manufactured on the same production line, the inclusion of robot tool changers offers manufacturing flexibility enabling future production lines to produce vehicles in a flexible manner to answer changing customer demands.

Focusing on functional reliability

Whether in press shop, body-in-white lines or in assembly, the functional reliability of the changers plays an essential role every time. The failure of a tool changer can have fatal consequences, particularly in production lines where hundreds of robots are used. If only one of the systems fails, the entire line stops.

In the design of its own tool changers, Stäubli has concentrated primarily on the heavy payload area and covers nearly every imaginable application in the load capacity range up to 1,530kg with torsional moments of up to 12,500Nm. The tool changers can be equipped with various modules and components for media, data and electrical energy supply corresponding to the customer-specific application. The innovative products are based on know-how gathered from nearly 60 years of experience in coupling and connection technology. Valuable synergy effects also arise from close collaboration with the in-house brands Stäubli Robotics and Multi-Contact. The result is technologically leading tool change systems with superior performance.

In the process, the manufacturer defines performance not only by productivity, but also safety. Stäubli offers tool changers in various customer-specific designs. Stäubli pays particular attention to adherence to Safety Category 3, Performance Level d. For this exacting standard, Stäubli has the appropriate certification accompanied by long-term know-how, by means of which the optimal layout of all possible changer variants can be found quickly. In this case the tool changers speak the user’s language. This means the systems are compatible with all common bus systems and can be operated without limitation using the likes of Profinet, Profibus, Devicenet, Interbus and other systems.

The tool changers can be configured to meet a wide variety of customer specifications. The modules can be flexibly positioned around the locking system to fit our customer´s connections. Precision-fitting coupling modules for the widest-ranging media are available for each application. The locking mechanism serves as the basis. It must function quickly, safely and reliably under the dynamic forces which arise during robot movements even in the event of a power failure. The locking unit is an important component in regards to production quality as it ensures repeatability.

The modular design of tool changers with the widest variety of combination possibilities enables their precise configuration design for the customer-specific task. As a result, systems can be configured quickly and can be easily adapted to changing conditions. A large number of different modules is available and can be exchanged or integrated at a later time.

Seven different module types

The modular system is basically comprised of seven different module types: a pneumatic and cooling module, a MultiDNet module for the signal and power supply, a primary circuit plug connector for welding current, a fibre optic cable, a mass flow module, and a high-pressure hydraulic module. The material transfer module enables fastener systems to transfer fasteners such as rivets, screws, studs, etc. through the tool changer to the tool. All modules are available in various versions and sizes, such that the theoretically possible number of different variants lies in the six-digit range.

Along with the large number of solutions, Stäubli offers docking stations for the tools which are precisely tailored to customer specifications. The layout of the docking station is also based on a modular design from which all customer-specific variants can be derived. Even special requests such as weld gun cooling in docking stations is easy to integrate with the Stäubli Multi-Coupling technology. As part of an intelligent system, the docking stations are equipped with integrated safety systems which prevent accidental unlocking and thereby prevent damage to tools.

Stäubli tool changers are used worldwide by leading automobile manufacturers. The systems have been proven in round-the-clock multi-shift operation in continuous industrial use for many years. The consistent quality, in-house level of vertical integration and decades of expertise in coupling technology make the Stäubli tool changers reliable automation components which assure the maximum efficiency and cost-effectiveness of every robot using them.

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