Manufacturing companies often need to scale their capabilities and capacity quickly to meet the demands of customers serving high-volume markets such as automotive components, building automation, and IoT. Winning a tender to supply original components to a big automotive brand is a major coup for a parts maker and is a cause for celebration.

On the other hand, the win also challenges the supplier to meet obligations that are often complicated and can demand careful investment in new automation. The customer may order a relatively small number of units to test the water before placing major orders, and there may also be a ramp-up period.

A small business needs to be smart to manage the transition from being the winning tender to becoming a trusted long-term partner. Financially, making a large up-front investment in new equipment may not be feasible and risks being left with over-capacity if the business ultimately goes in a different direction. On the other hand, they need to be ready to deliver according to the agreed schedule as soon as they get the green light.

Free pallets automation

Free pallets is a flexible and scalable approach to automated manufacturing processes. Using free pallets automation is widely appreciated as a flexible approach to manufacturing products continuously, in high volume. The workpieces are mounted on pallets that move independently between workstations, usually on a conveyor or track system. They are not rigidly fixed and can be stopped, rerouted, or buffered as needed.

In a typical free pallets process, automated equipment at each station performs a specific task on the workpiece carried by the pallet, such as welding, assembly, or inspection. The pallets move asynchronously, each at their own pace, depending on the time taken to complete the process or availability of the next station. Pallets can be diverted to different paths or stations based on the product type, quality checks, or production logic. Because the pallets can queue between stations, upstream and downstream processes can operate at different speeds.

There are inherent advantages in this approach that are of particular benefit to small manufacturers. Extra stations can be added quickly and cost effectively, or unneeded stations removed, without redesigning the whole line, thereby easing scalability and letting businesses adapt as customers evolve their requirements. Also, by directing different products to follow different paths, small businesses can support mixed-model production and customise individual units if required. In addition, by decoupling the process timing between stations, automation with free pallets minimises bottlenecks and ensures resilient and maintenance-friendly manufacturing. If one station stops working for any reason, other stations can continue.

Automation with standard conveyors

Automotive components, smart heating controls and other engineering assemblies are often produced this way, enabling manufacturers to optimise flexibility and uptime. In an EV battery assembly line, for example, the battery modules are placed individually on their pallets and move through the sequence of processes. The first process may perform an automated inspection before the pallet moves to the next station for automated screwdriving. The final station then completes the sequence by laser welding the battery pack. If the welding station is busy, the pallet can wait or can be rerouted to an alternate welding cell.

Free pallets has proved effective in numerous manufacturing scenarios. Yamaha Robotics has worked with the systems integrator El.Mec, from northern Italy, which has created modular manufacturing cells for free-pallets processing using robots from the extensive Yamaha SCARA portfolio. The cells leverage an innovative design with standardised external electrical and mechanical interfaces that can be connected directly to other cells when the time is right to extend the production line for increased production output or faster throughput. This lets equipment operators scale-up their production lines even more quickly and easily than is possible in a conventional free pallets line.

The cellular concept helps manufacturing companies bid for large contracts despite having only limited capacity, confident that they can accelerate throughput and adapt individual processes as needed to fulfil their obligations throughout the lifetime of the project. Each cell contains a set of production stations and, by integrating Yamaha SCARA robots, these stations ensure fast and efficient cycle times when assembling and handling workpieces such as valves and small mechanisms. The stations can be manually withdrawn for maintenance, adjustment, or adaptation if required.

Faster and more flexible

By also integrating the Yamaha LCMR200 linear transfer system, the latest generation of this standardised cell can operate at a higher line rate than is possible when transporting the workpieces using conventional conveyors. Powered by linear motors, the LCMR200 sliders travel at up to 2500mm per second. The speed, acceleration/deceleration, and stop positions are programmable, and therefore easy to setup, fine-tune, and adapt as needed.

The sliders can carry up to 30kg and can hold the workpiece accurately to let the robots perform processes such as screwdriving, glue dispensing, or palletising without dedicated tooling. The cells are thus easier to use and setup, throughput is enhanced, and the system is also extremely quiet, even when operating at full speed.

The sliders are driven independently and encoders feed back position information continuously to the main controller. In addition to letting the system optimise throughput and prevent collisions, the position and timing data can drive quality control and process improvement. Moreover, the information also enables per-unit traceability thereby simplifying compliance with automotive industry requirements. The position data is captured automatically with no user intervention or reliance on conventional identifications systems such as RFID, thereby helping avoid extra costs and engineering effort.

By integrating the linear transfer system, the assembly cells can be interconnected with extreme accuracy as the production line is scaled up. The mechanical tolerance between the sliders is closer than ±30 micron and circulation units installed at the end of the line utilise high-rigidity guides and a closed-loop system to eliminate any deviation due to ambient temperature variations.

Free pallets automation is a proven manufacturing technique that delivers flexibility for operators and can scale when needed to increase production capacity and throughput. Further enhancement, introducing standardised, interconnectable production cells and Yamaha’s linear transfer system unleashes extra speed and faster scalability, to let small manufacturers handle big contracts more confidently.

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Injection molded parts tend to be produced in large volumes yet, at the same time, quality expectations are high. Even small cosmetic defects can be easily visible, while perfection in terms of form and dimensions is often critical in parts for applications like automotive components, electronic connectors, medical syringes, and surgical tools.

Contractors that specialise in this field can offer advantages such as cutting-edge design knowhow and process capabilities to OEMs that may have only limited in-house expertise and manufacturing capacity. With the potential for fast turnaround and economies of scale, they also need to ensure top-notch quality control and customer support. Yamaha has helped to raise the game in both respects with a solution bringing together the low-cost YK-XE SCARA, RCXiVY2+ vision system, and YRG electric gripper.

Quality control challenge

With an array of automated injection molding machines operated continuously, producing molded items at an extremely fast rate, shift workers were fully occupied palletising items as they were removed from the machines by high-speed take-out robots.

The established process flow involves these robots removing the freshly produced items from their molding cavities at the end of each cycle and placing them on a constantly moving conveyor. The conveyor transports the items towards the palletising station, dropping them into a collection box at the end of the belt. From this box, an operator picks the items one at a time to inspect visually and place in the pallet, discarding any that are seen to be defective.

The production team noticed that items could easily become damaged by impacts and rubbing when dropped in the box. Moreover, the box effectively randomized production, preventing the team from tracing any defective molding back to its cavity of origin. In addition, operators had little time to inspect each item, giving the possibility for defective units to be passed as OK and packed for shipping to the customer. They saw the opportunity to strengthen quality control in the factory while also addressing staffing challenges.

“Picking, inspecting, and palletizing the molded products, at a high rate, for the duration of a shift, is repetitive work that demands a high level of concentration. It’s not a popular job and this company was having difficulty finding people to work in those conditions,” comments Tatsuo Katakura, Sales General Manager at Yamaha Robotics FA Section. “A SCARA robot is the perfect starting point for a solution to quality control and automation challenges like this and our YK-XE range offers the opportunity to lower the cost of ownership by saving quality control overheads.”

Improving efficiency

Working with the customer to implement a solution, Yamaha engineers chose the YK400XE-4 from the low-cost, high-performance SCARA portfolio to take care of palletising the molded parts. Its 4kg payload capacity is ample for handling the small items and the arm structure, specially optimized for low vibration at high speeds, allows an extremely fast cycle time of less than 0.4 seconds; fast enough to keep pace with the work rate of multiple molding machines and take-out robots operating upstream.

With its arm length of 400mm, the YK400XE-4 has the perfect reach to pick items from the 300mm-wide conveyor and place them directly in the pallets that are 300mm deep and 400mm wide, as figure 2 also shows. Alternatively, the team could have chosen a SCARA from the YK-TW omnidirectional range.

By transferring the molded pieces directly from the conveyor to the pallet, the engineering team achieved two important goals. Firstly, items are protected against damage as they are no longer dropped into the collection box. Moreover, the SCARA can automatically associate the position of each item as it is placed in the pallet with its originating cavity ID. Recording this information can help the company strengthen quality control and drive improvement initiatives, as well as provide traceability information for customers if required.

Easy to integrate vision

To track items as they move along the conveyor, and thus calculate the position for the SCARA to pick each one from the correct location, the team turned to Yamaha’s RCXiVY2+ vision system. This system is conceived to integrate easily with the SCARA and is controlled from within the RCX robot controller. “Unlike conventional approaches that often require specialized computer vision expertise, the project team in this case was able to integrate the camera and accomplish the complete system setup independently within a short timeframe,” observes Tatsuro Katakura.

Yamaha has created special vision instructions that simplify programming for robot engineers. Directly integrating vision in the RCX controller saves coordinate conversion, which is often needed when mapping third-party vision data and robot point data, and it’s easy to calculate position whether the camera is in a fixed position or mounted on the robot. The robot program also controls the camera optics and lighting system.

“The RCXiVY2+ system has powerful features built in, including conveyor tracking for accurate high-speed pickup, random part-position searching, on-the-fly adjustment for orientation, and OK/NG judgement,” adds Katakura. “There is also a special blob detection function, which is up to 10 times faster than conventional edge detection, to quickly position the robot when picking up irregular shaped items.”

To complete the project, the team chose a YRG series gripper from the large selection of off-the-shelf accessories available directly from Yamaha. Like the RCXiVY2+ for robot vision, these electric grippers are controlled from the main RCX340 multi-axis controller and designed to be easy to use, requiring no data exchange with the host system. Leveraging full electric control of the gripper, the team was able to quickly configure and optimize parameters including speed, positioning, and gripping force, with sensor-free detection in the event of mis-gripping or dropping.

By accomplishing this project, introducing a robot to palletise injection-molded components has improved quality control, increased efficiency, and enabled the business to introduce traceability, which had been impossible to achieve before. The project team was able to highlight the advantages of the new system within the company, seeking the green light to expand the solution to other lines in the future.

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The business of making and selling is constantly evolving. Factory operators must respond to multiple forces for change; in markets, among competitors, from legislation, and the potential for disruptors to enter the competitive landscape. In the perpetual search for improvements, automation is a powerful tool that also demands significant financial investment and commitment of time and resources. Hence, planning properly is vital and the decision making must also recognise that the chosen automation, when installed, becomes part of the changing scene where flexibility is essential.

Robots have been widely regarded as a technology that can take over labour intensive manual tasks, but they can also offer a flexible, compact, and reprogrammable alternative to conventional factory automation. Machines in established formats, such as SCARA and cartesian robots, are available in small sizes, with arm length from over one metre down to a few centimetres. They can be rated for carrying loads from as much as 40-50kg down to less than 1kg and the fastest SCARA machines have cycle time below one second.

The broad choice of different types and sizes gives factory planners many options when seeking a suitable solution. They can begin by changing one process that may be causing a bottleneck, or change an entire assembly line that may involve any combination of manual work and conventional automation.

When beginning to evaluate robot-based automation, it is important to identify the locations the new machines can be deployed most effectively, for the greatest improvement. Starting with a small-scale implementation, migrating just one or a few processes to a robot-based implementation, is often advised. By starting small, a functioning solution can be realised relatively quickly and the project can highlight key implementation challenges that show where extra knowledge may be needed to accomplish subsequent projects. The experience gained can inform these activities as automation is expanded to encompass other processes in the production line and across the factory floor.

Since speed, accuracy, strength, and endurance are major advantages of robots, in addition to their programmable flexibility, introducing them in industrial processes can take advantage of one or a combination of these attributes. Their lifting capabilities are one example. Some industrial products, such as EV battery modules, can weigh between 30-50 kg.

On the other hand, containers filled with liquids such as engineering oils or cleaning fluids can weigh just a few kilograms. Introducing a high-speed SCARA robot at the end of the line can improve productivity by taking over the repeated lifting and moving, which can eventually become tiring for any human operator over the course of a shift. Fatigue brings an increasing probability of injury.

Moreover, the robot is capable of placing the item accurately in a required position. A human worker’s accuracy will deteriorate over time, particularly if the items weigh a few kilograms or more.

Implementation

Yamaha Robotics has demonstrated solutions that implement end-of-line processes using robots, including a test and assembly station for electric vehicle batteries, at recent industry exhibitions in Europe. This battery module handler illustrated heavy lifting, rapid positioning, and accurate placement of 35kg lithium-ion modules in a test fixture for electrical testing, followed by stacking the modules in battery packs.

Accuracy is another strength of SCARA robots and smaller machines can take over precision assembly tasks such as press-fitting components or driving screws. Pneumatic screwdrivers are widely used in assembly areas, to help operators work quickly and ensure the correct torque is applied. However, errors can occur. One example is where screws are required to be inserted in deep holes. Some can be missed as operators cannot see whether a screw has been inserted. Automating the screwdriving processes provides certainty that every item is inserted and tightened satisfactorily.

A robot installed at a specific workstation in the production line can take over a task like screwdriving and significantly improve overall production yield and quality assurance. An articulated robot, or cobot, can perform the task in much the same way as a human operator, ensuring greater repeatability. Alternatively, a SCARA robot, integrated together with a suitable screw feeder in a compact work cell, can deliver the superior repeatability as well as an extremely fast cycle time. The smooth motion control that characterises SCARA robots also makes these machines ideal for dispensing air-curable adhesives, gasketing materials, or sealers.

Another popular approach is to deploy robots in offline processes, such as testing electronic assemblies and personalising or individually configuring products before storing in inventory or shipping to a customer. In 2024, Yamaha demonstrated a solution that configures electrical connectors in accordance with instructions in a network file. The cell contains a SCARA robot that selects and loads the appropriate punching tool, with integrated vision to verify the correct pins have been punched and that there are no burrs.

The process is guided by barcode to prevent errors and can handle different connectors in the same operation. Automated loading and unloading of electronic assemblies into a test fixture for in-circuit and functional testing was also demonstrated, based on a cartesian robot to ensure precise positioning of the assembly for electrical continuity.

Selection and optimisation

Creating a turnkey automation solution demands a combination of skills to bring together robots and software, application-specific tooling, and system integration. To ensure the robots can operate as efficiently as possible, the workflow and physical layout of the plant may need to be adapted.

Suitable simulation tools can provide valuable help to plan the production line, select the most appropriate types of automation for each process, and optimise the cycle time and throughput. By providing tools to create digital models of production lines, simulation software helps visualise layouts and workflows before physical implementation, as well as helping to pinpoint any bottlenecks or other inefficiencies in the system by simulating the flow of materials and processes and the interactions between robots, other automation, and people throughout the factory area.

Simulating with tools such as the Robot Simulator in Yamaha RCX Studio permits experimenting with different configurations, equipment placements, and workflows. This enables project teams to find the most efficient setup before committing to hardware or making any physical changes in the factory.

Working with appointed sales agents and system integration partners, Yamaha continuously works on developing robot cells for specific manufacturing challenges. Drawing on these experiences can help expedite solutions to commonly encountered issues

Automating with robots can deliver an effective solution to enhance manufacturing productivity, while ensuring flexibility to adapt to changes in production requirements or product design features. Whether deployed inline, or in standalone processes performed offline, robots can be introduced selectively to prove the approach and build experience before scaling up to automate an entire sequence from end to end.

Simulation is a powerful tool that can augment careful study into optimising processes, the positions of robots in the line, and the cycle time, to achieve the highest possible equipment utilisation. The skills and knowledge of external organisations, including the robot supplier and system integrator are essential to realise an effective and optimised solution.

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Building on connections with system-integrator partners, the booth will show how the feature-rich LCMR200 maximises the value and performance of Yamaha robots automating industrial processes. The first is a fully automated coil assembly system that visitors can see in action during the show. The LCMR200 enhances positioning precision and control, simplifying the assembly line while boosting throughput and meeting high quality standards.

Visitors will also view the LCMR200 system combined with Yamaha SCARA robots for agility and scalability in next-generation production lines.

“Flexibility and productivity are increasingly critical in today’s factories and we are bringing new Yamaha solutions to automatica, and also those developed with system integrators, that show how to maximise both,” said Tatsuro Katakura, Sales General Manager, Yamaha Robotics FA Section.

“The LCMR200 has a key role in each, integrating perfectly with other robots and boosting the overall production to levels unachievable using conventional workpiece transport. We welcome everyone to visit us at automatica, booth B5.314, to experience the demonstrations.”

The Yamaha booth will feature additional displays of the LCMR200’s potential, including space-saving horizontal and vertical circulation units as well as a microelectronics assembly cell with built-in visual inspection. Also prominent at the booth, the lightweight and strong YK-XG series of SCARA robots offers arm lengths from 20cm to 1200cm, 50kg maximum payload, and cycle time below one second even when carrying a 40kg load.

The LCMR200 portfolio offers a range of accessories, including Yamaha’s traversing unit as well as the horizontal and vertical circulation units that demonstrate production line programming and save floorspace. The modules enable production lines to be quickly configured, reconfigured, and scaled to meet evolving requirements. They combine readily with Yamaha SCARA and cartesian robots to solve diverse production assembly, picking, packing, and inspecting challenges.

Yamaha product and automation experts, sales specialists, and partner representatives will be available at the booth throughout the exhibition to talk about the wide range of Yamaha robots. Visitors can learn how today’s industries can realise tangible productivity gains by leveraging systems like the LCMR200, advanced features such as Yamaha’s RCXiVY2+ vision, space-saving ceiling-mounted SCARAs, and special models for use in cleanrooms.

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Quantum computing, New Space, and smart mobility are some of today’s most exciting innovations. Producing critical components and subsystems, such as multi-qubit processors, satellite transceivers, and EV batteries, calls for extreme precision, cleanliness, and reliability. High-purity cleanrooms are needed and commercialisation of these facilities also demands suitable automation inside, including robots specially designed to meet international cleanroom standards.

ISO 14644 is the international standard covering the design and operation of cleanrooms, and comprises multiple parts that describe all applicable aspects including construction materials, protective clothing, precautions to be taken on entry and exit, and environmental categories defined by air quality. ISO Classes 8 and 7 are the most common cleanroom environments used by industrial companies. Class 7 allows 10,000 particles of size greater than 0.1 micron per cubic metre, while Class 8 permits 100,000 particles per cubic metre.

General pharmaceutical production typically takes place in ISO Class 7 cleanrooms, as well as assembly of medical devices, aerospace equipment such as satellites, and automotive electronics. On the other hand, ISO Class 8 is appropriate for a wide variety of manufacturing facilities and sensitive electronics assembly. As regulations and operational requirements in these sectors become stricter, the required standards are moving towards tougher standards such as Class 5. On the other hand, activities like semiconductor manufacturing, satellite optics, biotech, and some medical nanotechnology processes already demand ISO Class 4 and higher.

Cleanroom construction and management

To satisfy specified air-quality standards, incoming air is filtered to prevent large particles entering from outside. It is also important to consider how equipment and staff can introduce contaminants when inside the cleanroom.

Among the specifications aimed at preventing this kind of contamination, cleanroom construction guidelines mandate the use of non-shedding materials that do not easily release impurities such as dust, microbes, or fibres into the surrounding environment. Stainless steel is often used, for its non-porous surface characteristics as well as corrosion and wear resistance. Non-porous polymers and specialised anti-static and low-particulate plastics are also used effectively.

Recognising that human workers are a major source of unwanted contaminants, released from skin and clothing, rigorous cleaning and adherence to dress codes and changing at entrances and exits is a minimum requirement. Alternatively, automating as many processes as possible to minimise the number of workers needed can relieve burdensome hygiene protocols and improve the environment inside the cleanroom.

Robots are ideal to take over activities such as transporting, unpacking, picking, and placing components, building assemblies, and packaging completed products. However, if not designed carefully, these, too, can emit unwanted contaminants into the cleanroom environment.

Special features of cleanroom robots

The SCARA format is often the first choice of system integrators seeking to solve industrial handling challenges. For general-purpose, non-cleanroom use, belt-driven mechanisms provide acceptable strength and accuracy at a price that can be affordable for smaller manufacturers as well as large corporations.

In a cleanroom, belt drives and other standard components such as bearings and actuators experience wear that can emit quantities of particulates into the surrounding environment that would be unacceptable in a cleanroom. To overcome this, SCARA machines like Yamaha’s YK-XGC robots are specially designed for cleanroom use and contain durable beltless drives that minimise the wear rate in moving mechanisms. The Z-axis spline, which is typically exposed in non-cleanroom variants, is covered with a bellows made of a material with low dust generation. Also, other sliding parts as well as bearings and motors are sealed completely to keep any lubricants and dust inside.

In the same way that non-shedding materials are prescribed for cleanroom walls and other surfaces, the outer casings and panels of cleanroom robots are made from materials such as stainless steel as well as polycarbonates and low-outgassing or anti-static plastics. However, non-shedding materials are not a “fit and forget” solution. Equipment operators must care properly for the surfaces, including cleaning and maintenance to prevent corrosion or damage from compromising the non-shedding properties.

Where non-shedding materials cannot be used, such as in harnesses and cables, these are incorporated completely within the robot. Internal suction, built into the base of the robot, provides additional protection to prevent any particulates that may be generated from escaping. These cleanroom-specific SCARA robots are compliant with ISO 14644-1 for use in cleanrooms operating up to ISO Class 4 and Class 3 standards, enabling them to address some sensitive applications.

Recently, new YK-XEC cleanroom SCARA robots arrived, combining cleanroom features with cost-conscious principles suitable for use in ISO Class 4 environments. These robots are available in sizes from 400mm to 710mm arm length and payload capacity from 4kg to 10kg. They combine a compact design for low overall height with an optimised arm structure that reduces vibration and allows higher excursion speed that significantly reduces the cycle time.

For moving heavy objects weighing up to 120kg and more, across distances from 50mm to more than two metres, cleanroom-compatible single-axis robots are available built with stainless steel for the slide table surface. The slider section uses roller bearings to prevent dust generation by minimising friction. Other internal mechanisms are lubricated with special low-dust grease and an easily accessible suction port facilitates purging foreign objects as well as preventing dust from being emitted. Together, these features ensure compliance with ISO Class 3 cleanliness specifications.

Similarly, XY-XC clean cartesian robots for ISO Class 3 environments feature stainless steel construction and are available with two, three, or four axes. With excursion speed up to 1000mm/s and leveraging the same high-speed ZR-axis actuator of the SCARA robots, these robots ensure a fast cycle time.

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Intelligent machines that help us do more have existed in fiction for thousands of years. As early as the 8th century BCE, Homer’s Iliad imagined a team of skilled automata as metalworking assistants. In the real world of the 1970s, industrial robots – the name taken from Czech literature – brought superhuman strength, speed and repeatability to the automotive industry, performing tasks like welding and spraying.

During this time, Yamaha had developed its own Computer Aided Manufacturing Equipment (CAME) to support motorcycle production. In contrast to those large welding robots, the machines were small, highly functional and elegantly designed. In 1981, perceiving a broader role in industry for this CAME concept, Yamaha formed the first incarnation of its Intelligent Machines (IM) division. The founding team of about 50 staff included engineers from the production technology group, as well as newly hired specialists. However, the market for such equipment was unproven at this time and conditions were difficult.

For a while, activities ceased until the arrival of Katsuhiko Tsuchiya, returning to Japan from a posting as head of Yamaha’s California R&D Centre. He reformed the IM division and the team continued to work in a corner of the motorcycle factory. With general market interest in industrial robots continuing to grow, the team took the opportunity to show how their technologies could transform production processes and boost manufacturing productivity at the Tokyo International Robot Exhibition of September 1983.

At this event, visitors from a major electronic equipment manufacturer witnessed the demonstrations presented at the Yamaha IM booth. They got in touch to ask whether the knowhow on display could be used to make a small chip mounter for attaching electronic components to printed circuit boards. This small, high-precision, programmable machine became the forerunner for today’s surface-mount placement machines. Even now, high-speed inline surface mounters are the biggest selling items in the Yamaha Robotics portfolio. Infused with Yamaha’s robot technology, they deliver high speed, accuracy, repeatability, and flexibility, with many innovative automated capabilities that allow sustained fast cycle times with minimal errors; two of the main benefits manufacturers can gain by introducing robots in their activities.

The IM division continued to present new and more advanced concepts at exhibitions worldwide. As technological development continued, the orders taken at these events became more frequent and larger. These early projects included an assembly line for brakes and a photocopier manufacturing system. Since then, the division has delivered more and more robots to support production activities in an increasingly diverse selection of industries, such as assembling consumer electrical appliances, transporting automotive components, and producing large liquid crystal panels.

Industrial robots today

Building on knowledge and technologies developed for those early CAME machines, Industrial robots have evolved to become sophisticated and highly developed cartesian, SCARA, articulated, and collaborative robots. In addition, Yamaha’s LCMR200 modules embody robot technology to deliver high-speed, programmable workpiece transport as a quieter, more robust, reliable and flexible alternative to conventional conveyors.

The trend towards greater automation continues to grow in factories worldwide, as businesses seek to increase their productivity in all aspects of making, packaging, and handling diverse types of products. Robots are now widely adopted to accelerate process cycle times and minimise errors, while end-to-end automation of complete assembly sequences can improve workflow by enhancing synchronization between the individual processes.

Moreover, new markets and applications have emerged such as production of electric-vehicle batteries, which is ideally served by large SCARA robots. In 2023, Yamaha Robotics demonstrated a battery final assembly and test solution capable of repeatedly lifting and placing 35kg modules with extreme positional accuracy for electrical testing and final assembly.

Yamaha is also expanding the adoption of industrial robots to include smaller enterprises by engineering new products for a high performance-cost ratio. The YK-XE SCARA series is one example. Yamaha extended the portfolio in 2024 by introducing the YK-XEC cleanroom series. Meeting ISO Class 4 (ISO 14644-1) cleanliness standards, they are used in semiconductor fabrication, hard-disk assembly, medical device assembly, and food production.

Robots have come a long way since the enthusiastic engineers of Yamaha’s startup IM division began their quest in 1981. Their work has contributed to the development of a globally influential technology, developed and adopted by leading businesses and researchers. According to Fortune Business Insights, the global industrial robots market is estimated at $18 billion in 2023 and is expected to exceed $41 billion by 2030.

Atilla Saral, Yamaha Sales Manager, said: “The Raveo team has impressed us with their knowhow, energy and dedication to customer satisfaction, since we began working together in 2024. Having a strong business presence in Slovakia also, with an excellent reputation and many key contacts, they are perfectly placed to nurture new customers and build our brand in the region.”

“Teaming up with Yamaha has significantly increased our ability to tackle emerging opportunities for advanced automation. The robot portfolio offers excellent quality and great value and this expansion of our remit will bring futher exciting opportunities to create winning solutions for our customers,” added Aleš Zapletal CEO of Raveo.

Raveo is an expert in industrial automation, specialising in high-speed, precision motion and positioning, and offering services across the complete engineering lifecycle including technical consultations, mechanical and electrical design, software and after-sales support. The team’s expertise in drives, actuators, and mechatronic systems provides the foundation for delivering tailored solutions that leverage the precision, speed and many unique features of Yamaha’s robots.

Yamaha brings an extensive portfolio including the LCMR200 linear transfer system with unique features including bidirectional motion and circulating and traversing units. There are also SCARA robots in a wide range of configurations from extra small models down to 120mm arm length, clean-room variants, ceiling-mount orbit types for working in narrow spaces, and large SCARA units that can handle payloads up to 50kg.

There are also cartesian, single-axis, and multi-axis robots. Users can take advantage of tools such as RCX Studio that permits easy graphical programming and a 3D simulator and RCXiVY2+ Studio that simplifies programming the optional RCXiVY2+ machine-vision system.

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“Automating the right processes in the right way is critical for today’s enterprises, which are challenged to reach ambitious productivity targets,” said Tatsuro Katakura, FA Section Sales Manager. “Robots are ideal for tasks such as assembly, packaging, handling, moving, and sorting, and we have carefully chosen our distribution partners for their ability to deliver and support effective solutions. By bringing everyone together at the distributor meeting, we can showcase our latest technologies and share perspectives on customers’ needs in diverse industries.”

Key topics included opportunities for Yamaha’s LCMR200 linear conveyor modules, which provide flexible workpiece transport, and innovations among the SCARA, cartesian, and multi-axis families. Also, after reviewing milestones such as the completion of new manufacturing facilities in Japan that increased robot production capacity and established Yamaha’s first carbon-neutral factory, the meeting set out strategies for the year ahead.

Mr Katakura added: “Our partners have all worked extremely hard this year to drive new projects, grow sales, and provide support that ensures solutions based on Yamaha robots deliver the best possible results for customers.”

He concluded the meeting by presenting the FA Section’s annual awards for performance over the preceding year, including the Sales Achievement award to A.T.T.I, which covers Italy, the Special Contribution award to Raveo, distributor for Czechia, and the Top Service award to Seika Sangyo of Germany.

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Since last year’s event, where visitors saw the YK1200X SCARA lifting and accurately positioning 35kg EV battery modules at high speed, the team has been hard at work integrating robot skills many other scenarios. On the booth this time, a robotic punching machine will show configuring electrical connectors with relentless precision.

Another solution will illustrate high-speed sorting and palletizing of small engineering components. Each contains a fully integrated Yamaha robot for picking, positioning, and accurately placing the components, maintaining fast and consistent cycle time and operating for prolonged periods without intervention.

Also in action, an automated in-circuit and functional tester will show how robotic loading and withdrawing of test assemblies cuts cycle time and enhances quality control. The EV battery end-of-line handling demonstrator will be on the booth again to demonstrate the strength, speed, and repeatability of the YK1200X. With its 1.2-metre arm length and 50kg maximum payload, this SCARA can move heavy objects within a relatively large are to support activities in industrial production, packaging, warehousing, and shipping.

“At Motek 2024, we will continue our mission to show how Yamaha robots in a wide variety of sizes, down to compact benchtop units, can enhance productivity in numerous industries,” said Tatsuro Katakura, FA Section Group Manager. “Our demonstrations will show Motek visitors our collaboration with system integrators to deliver high-value solutions and lead to new dialogues and further exciting projects.”

The booth will also highlight Yamaha’s LCMR200 workpiece transport modules, with two demonstrations showing the horizontal and vertical circulation units. The LCMR200 delivers greater speed than conventional conveyors, with smooth linear motion, flexible digitally defined stopping positions, with numerous additional advantages including scalability, traceability, and easy maintenance.

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Atilla Saral, Yamaha Sales Manager, said: “Czechia is home to many industries that can benefit from flexible automation based on our high-performance robots and Raveo is perfectly positioned to create solutions that deliver outstanding value for customers.”

Aleš Zapletal, CEO of Raveo, commented: “By combining the precision, speed and many unique features of Yamaha’s robots with the knowledge and experience of our experts, we create innovative and functional solutions for customers that we believe will lead to great mutual success.”

Radek Kaňovský, also CEO of Raveo, added: “With Yamaha’s help, we are already positioned to begin supporting customers with our technical know-how and access to downloadable files including catalogues and 3D models now available online at Raveo’s website.”

Headquartered in Otrokovice, Czech Republic, Raveo is focused on industrial applications where motion and positioning are required, delivering technical consultations, optimal design and after-sales service for customers. The product offer includes mechanical and electrical components from renowned manufacturers, including electric motors, gears, linear actuators, mechatronic systems, and electronic drives. S

electing from these technologies, and leveraging the team’s expertise in industrial automation, Raveo has the skills to work with customers to develop and quickly deliver complete solutions.

The extensive Yamaha portfolio includes SCARA robots from extra small models with arm length down to 120mm, clean-room variants, ceiling-mount orbit types for working in narrow spaces, and large SCARA units that can handle payloads up to 50kg. There are also cartesian, single-axis, and multi-axis robots, and the LCMR200 linear conveyor modules that provide high-speed, programmable workpiece transport with simplified control, bidirectional motion, and flexible circulating and traversing units.

Users can take advantage of tools such as RCX Studio that permits easy graphical programming and a 3D simulator and RCXiVY2+ Studio that simplifies programming the optional RCXiVY2+ machine-vision system.

Visit the Yamaha website for more information

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