SG-series SCARA robots enable extremely fast and precise operation for small part processing in applications such as picking, packing, dispensing and handling of small components, especially in confined spaces.

Automation continues to make an important contribution in helping manufacturing and general industry improve productivity and reduce costs and the introduction of the SG-Series of robots will help to continue this trend, particularly where demand is increasing in sectors such as food, medical and cosmetics.

Two options are available, the SG400 with a payload capacity of 3kg and a maximum reach of 400mm and the SG650 offering a payload capacity of 6kg and a maximum reach of 650mm. They feature small interference contours which allow the robots to work together while the internal cabling ensures a reliable workflow and reduces maintenance.

Yaskawa has a well-established range of cost-effective robots for a wide range of applications including the smaller MotoMINI, GP Series and the HC Series. Part of the thinking behind the design concept of the SG Series was to combine the proven features and benefits of these into an even more compact, yet robust horizontal articulated scara SG Series.

The SG Series are driven by the compact and lightweight YRC-1000 micro controller for small Motoman robots providing high performance robot control in a small footprint cabinet which is optimised for smaller pick and place, assembly applications.

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The company is opening a 35,000sq ft facility at Hillthorn Park adjacent to Nissan UK and the International Advanced Manufacturing Park (IAMP).

The new UK headquarters marks a continuation of the company’s ambitious expansion strategy in Europe. Yaskawa Electric Corporation founded in Japan in 1915, is consciously following the trend towards building up technology know-how and production competence in Europe.

The drives and motion products are manufactured in Cumbernauld, Scotland while 80% of the European robot demands are produced in the European robot plant at Kočevje in Slovenia.

One of the industries the company has seen present new opportunities for growth over recent years however is the electric and hybrid vehicles sector, which was a key motivator when moving to Hillthorn Park.

David Walsh, managing director at Yaskawa UK, said: “We continue to see positive growth and investment changes across our European organisation which includes the continued desire to invest in the growing opportunities for UK markets in the robotics, drives and motion control industries we work in.

“So, it really is a huge vote of confidence in the UK and our new location in the North East is a huge driver for major industrial investment and opportunities to help shape, create and contribute to innovative automation solutions for several industries such as automotive, food and beverage, logistics, packaging, manufacturing, wood and metal working, etc.

“As a business, being close to customers is extremely important to us and this move binds perfectly with that, putting us right at the heart of one of the UK’s largest manufacturing clusters and some of the biggest names in EV development and production.

“We also have plans to continue growing our headcount over the course of the next year and this will give us the space required to enable that, as well as ensuring we can continue to tap into the region’s rich talent pool of skilled workers.”

Situated just a short drive from the International Advanced Manufacturing Park (IAMP) and within an hour’s drive from Newcastle International Airport, the £60million business park is being developed by Legal and General.

Once complete, the site, supported by funding from central government, the North East LEP and the European Regional Development Fund (ERDF) – will deliver 620,000sq ft of prime industrial space in Washington, with 11 commercial buildings ranging in size from 21,550 – 124,250 sq ft.

“Globally, we’re committed to becoming a more sustainable business and futureproofing our operations and the move to Hillthorn Park is a perfect example of that,” he added.

“As a newly built facility, it is far more environmentally friendly than our previous sites and it’s a real vote of confidence from our HQ for our business plans not only in the North East but the UK as a whole, and we can’t wait until next Spring when we can move in. It’s a really exciting time for the business.”

Yaskawa has been supported in its move to the city by the Business Investment Team at Sunderland City Council. Cllr Graeme Miller, leader of Sunderland City Council, said: “We are fortunate as a city to be home to a number of multi-national manufacturers, and we are delighted that Yaskawa will soon join the ever-growing list of businesses that can now call Sunderland home.

“Through the development of Hillthorn Park and IAMP, our goal was to attract more inward investment into the city and create more highly skilled jobs for residents and in Yaskawa we have a company helping us to achieve just that.

“For the best part of a century, the business has been at the cutting-edge when it comes to developing automation and robotic technology, so it is fantastic to see such exciting career opportunities being created for local people.”

Helen Golightly OBE, chief executive of the North East Local Enterprise Partnership, said: “Yaskawa’s decision to invest in Sunderland reinforces our region’s position as one of the most important advanced manufacturing hubs in the UK. The company’s new state-of-the-art manufacturing facility at Hillthorn Park will bring more jobs to our region and help attract future inward investment as more businesses look to benefit from our skilled workforce and world-class infrastructure.

“The £2.5m investment from government’s Getting Building Fund, which is managed in the region by the North East LEP, has helped ensure this strategic Enterprise Zone site has the utility infrastructure to meet the needs of incoming businesses. As a result, one of the world’s leading global technology companies has chosen the North East as the base for its new UK headquarters, and the future growth of its business.”

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The centre offers the flexibility of a full turnkey solution for those requiring either a new automated facility, or the ability to upgrade to a current manual or automatic installation enabling customers to apply both solvent and water-based paints using Yaskawa Motoman’s painting robot and the Graco ProBell.

An important focus of the technical centre is its support of the full turnkey approach. This includes: painting robots, electrostatics, rotary atomisers, air guns, up to 3k auto mix, paint mix and supply, complete booths, conveyor systems, 3D programming, safety planning and ATEX. Also, it can be used to provide customer training in all aspects of automated painting, from mixing and paint supply, through to robot programming and maintenance.

The engineers at Peak Contracts will work with 3D offline programming to understand the Yaskawa Motoman robot requirement in terms of reach and available cycle time. The 3D models which can be imported into Yaskawa MotoSim, ensures rapid reach studies and robot programming. This enables customers to choose from the wide range of Yaskawa robots to ensure the most suitable and cost-effective solution for each application.

The in-house design team will then be able to establish a booth design to house the required robots and equipment, together with the controls department to size and design any conveyor system of handling equipment required for the turnkey solution.

Peak Contracts offer full paint trials in the new centre and working together with paint supply companies and the customer means that the full set of painting parameters can be tested helping to establish film builds, appearance and laydowns of the desired coating. The various settings of the Yaskawa robots, such as path speed, tool centre point and atomiser settings can be calculated and approved together with all stakeholders in the project.

Commenting on the collaboration with Peak Contracts, Yaskawa’s UK sales and marketing manager Jonny Grey said: “Yaskawa Motoman offers manufacturers a wide range of robotic solutions for today’s automated paint finishing applications as demonstrated by this successful collaboration with Peak Contracts and their paint delivery partner Graco.”

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These fully integrated systems offer the distinct advantage of being self-contained, so it’s a bit like buying any machine tool, you choose the size of machine you need and a location to install it – and away you go.

ArcWorld HS Micro and RS Mini Robotic systems are easy to install and simple to operate, occupying a small footprint of either 2.3 sq metres for the Mini, or as little as 1.4 sq metres for the Micro. Both systems offer the potential for operators to double their output with up to half the preparation time, compared to manual welding.

The Micro system is supplied complete with robot and controller and its hinged door opening provides lots of options, even though it’s a very small, compact system. The Mini system has a revolving door and table, which again means maximum flexibility within a compact system.

The systems are designed to allow quick changes of jigs, which is crucial in helping to reduce the all-important set-up time and improving production output compared to conventional manual welding practices. Additionally, improved operational consistency by never missing a weld and ensuring the same quality of weld at the end of the shift as at the start, also means reduced ‘spatter’ which improves the capacity for fettling.

Both systems incorporate a MOTOMAN-AR900 robot with YRC1000 controller, a start/stop button panel and fume extraction hood. They also feature a platform and casing with dark green polycarbonate glare shield protection and CE-marking.

The Yaskawa Motoman ArcWorld Micro and Mini robotic welding systems are pre-engineered, pre-assembled and shipped ready to weld and represent the latest generation of cost-effective automated solutions for welding applications. They can be configured with your choice of welding power source and are ready to mount your component tooling.

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MOTOMAN PL robots include newly tuned kinematics and the latest generation of Sigma7 drive technology which help to improve stability, increase payloads and cycle times. This optimises the performance of these versatile, all-round robots, which are ideal for automatic palletising and de-palletising applications.

The PL range comprises six models with a payload range between 80kg and 800kg and so cover an extremely broad spectrum of high-performance palletising tasks including classic final packaging applications which are becoming increasingly automated in today’s manufacturing and distribution logistics.

Thanks to their compact design and small footprint, Motoman palletising robots ensure optimum use of space for the set-up of compact palletising cells. Media cables for grippers can be connected, protected and are collision-free as they are fed through the robot base and inside the arm through all axes and also the hollow wrist.

Control, planning tools and programming

All the models in the Motoman PL range work together with the compact, high-performance YRC1000 controller that incorporates a wide range of functions for path planning and communication. The controller used on the medium to larger robots also features an innovative power regeneration function which enables energy to be generated when the motor is decelerated and has proven to reduce energy consumption by up to 30%.

The controller also synchronises the movements of function grippers or tracks while an optional functional safety unit (FSU) provides an ideal performance combination as it safeguards and minimises the most compact workspaces.

The integral MotoLogix interface enables PLC system programmers to program these robots in their customary IEC61131 conformant PLC programming environment. Another important benefit of this interface is it removes the need for a dedicated robot programmer and also integration into the PLC controller is greatly simplified.

The MotoSim VRC simulation software allows for easy design, planning and simulation of palletising cells. With a self-explanatory user interface Yaskawa’s optional PalletSolver palletising software simplifies programming of pick-up and depositing patterns as well as layer patterns which ensures numerous application specific features such as mixed palletising or multi-grippers.

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At the heart of the automated system is a MOTOMAN GP7, one of the most successful robots developed by motion control and robotics specialist Yaskawa. The GP7 is an agile and compact universal robot with a 7kg payload, up to 927mm reach a repeatability of ±0.01mm.

Scherzinger Pumpen was looking for a suitable automation solutions partner to help them achieve their aim of gradually increasing the level of automation in their production processes. EGS Automation, located close by in the Black Forest, offered the necessary expertise with a portfolio of robotic based automated systems dating back to 1999, involving the installation of over 2,000 robots.

For this automated processing application the EGS SUMO series was ideally suited to meet the requirements, specifically the SUMO Multiplex a 12-fold production system based on the ‘paternoster principle’ – proved to be the best option.

Component handling is performed by the compact, 6-axis jointed-arm MOTOMAN GP7 robot which is attached to the system, delivering a fast travel speed and high accuracy to ensure rapid, reliable and accurate part changes in the processing machine. The system incorporates an innovative side-shifting device which allows the entire unit to be shifted on its side in seconds, giving full access to the grinder. The system can also be quickly pushed back in front of the machine and precisely indexed so that it can swiftly resume automatic operation.

Workpieces are loaded and clamped into the machine with typical machining times achieved between 3 and 5 minutes. The components are then stacked on universal pallets which are adapted for the respective workpieces by means of component-specific plastic clips.

Thanks to the large storage capacity of the SUMO machine an automated runtime over one to several shifts, in some cases over an entire weekend, is achieved without the need for human intervention, depending on the component.

The robot is equipped with a double gripper tool which has jaws specifically designed for the workpiece portfolio to ensure the maximum number of shafts can be loaded onto the pallets. The robot picks them up from the pallet at one end of the shaft, places them into a gripping station then picks them up again before placing them in the machine for clamping. During unloading, the workpieces return to the pallet in the opposite direction.

The ultra-compact design of the GP7 robot enables it to be positioned closer to machines and fixtures – helping to save valuable floor space. They also feature a parallel-link construction for strength, rigidity and stabilisation of high inertia loads, along with heavy-duty bearings which ensure a smooth arm rotation.

In addition to their ability of handling heavier loads, these new models also offer the benefits associated with MOTOMAN robots, such as optimum productivity with high payloads and speeds. They also allow for a wide variety of products to be transferred with different grippers to ensure greater allowable movement. Speeds of all axes have been increased, whilst acceleration / deceleration control has been improved to achieve maximum reduction of acceleration / deceleration time for all robot postures.

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The YRC1000 robot controls are able to convert kinetic energy from the down and sideways movements directly into 400V AC at 50 Hz and feed it back into the grid. Depending on the movement pattern of the application, the robot’s energy requirements can be significantly reduced.

Reducing energy consumption in today’s highly competitive industrial environment is likely to be higher on most, if not all of today’s manufacturers’ agendas, especially due to current higher energy costs. With automation playing an increasingly important role in many applications maximising the efficiency of robots will be of significant interest across all manufacturing sectors.

Features such as regenerative braking can make a big difference to the efficiency of robots, recovering braking energy and feeding it back into the power grid without the need for additional hardware.

In applications such as handling, palletising, joining and processing, industrial robots make many down or sideway movements during which the servomotors dissipate energy thereby potentially generating electricity. Up until now, in older or other robot models on the market, the resulting energy has been converted to waste heat by control technology through electrical resistance and lost to the environment. In the Yaskawa solution the electric energy is fed back into the operator network – without the need for additional hardware so it can be re-used.

The extent of savings obviously depends on the specific application and the robot’s individual movement patterns, although realistically savings ranging from 8 to 25% can be anticipated which may result in annual feed-ins of about 2,800 kWh, equivalent to around 1600 kg CO2 and £1200.

In addition, the slim and compact design of Motoman robots with low moving masses and fast application of brakes during movement intervals enables the active position control to be switched off when not in use which increase the potential for greater efficiency.

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The company says these new features help to improve stability, increase payloads and cycle times enhancing the performance of these versatile, all-round robots which are ideal for automatic palletising and de-palletising applications.

The new series comprises six models with a payload range between 80kg and 800kg and so cover an extremely broad spectrum of high-performance palletising tasks including classic final packaging applications which are becoming increasingly automated in today’s distribution logistics.

Thanks to their compact design and small footprint, Motoman palletising robots ensure optimum use of space for the set-up of compact palletising cells. Media cables for grippers can be connected, protected and are collision-free as they are fed through the robot base and inside the arm through all axes and also the hollow wrist.

All the models in the Motoman PL range work together with the compact, high-performance YRC1000 controller that incorporates a wide range of functions for path planning and communication. The controller used on the medium to larger robots also features an innovative power regeneration function which enables energy to be generated when the motor is decelerated and has proven to reduce energy consumption by up to 30%.

The controller also synchronises the movements of function grippers or tracks while an optional functional safety unit (FSU) provides an ideal performance combination as it safeguards and minimises the most compact workspaces.

The integral MotoLogix interface enables PLC system programmers to program these robots in their customary IEC61131 conformant PLC programming environment. Another important benefit of this interface is it removes the need for a dedicated robot programmer and also integration into the PLC controller is greatly simplified.

The MotoSim VRC simulation software allows for easy design, planning and simulation of palletising cells. With a self-explanatory user interface Yaskawa’s optional PalletSolver palletising software simplifies programming of pick-up and depositing patterns as well as layer patterns which ensures numerous application specific features such as mixed palletising or multi-grippers.

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The Signature range encompasses the GP Series which means there is a model to suit a wide range of applications and requirements including the GP7, GP12, GP20, GP25, GP50, GP88 and the GP180. This represents one of the widest ranges of robots covering payloads of just 7kg and a range of 927mm, up to the performance of the GP180 which has the ability to handle payloads as high as 180kg across a range of 2702mm.

The key benefits of the Signature range of robots are high accelerations, speed and energy efficiency, along with a compact footprint. They are finished in a distinctive elegant black design.

Within the YRC1000 controller a very fast multitasking CPU, an advanced operating system along with the superior Yaskawa Sigma7 high speed servo technology, provides outstanding path performance and advanced functional safety (FSU).

At its European factory in Slovenia, Yaskawa develops mechatronics and robotic solutions for companies throughout Europe, the Middle East, Africa and the CIS states. This substantial manufacturing capability, combined with having subsidiaries in these regions along with European production sites, means they are located where their customers need them to be.

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A good example of this is the range of self-contained robotic systems from Yaskawa which has recently been extended following the introduction of the ArcWorld CS cell, a larger model added to the existing smaller HS Micro and RS Mini systems.

Based on a platform, the ArcWorld CS robotic welding station is designed with a host of user-friendly features which help to deliver the best performance, on the smallest possible space featuring a separate working area for the robot and operator respectively. The design means the robot, positioner, controller and power supply are all mounted on a self-contained common platform which also allows space for two welding robots, without the need to increase floor space.

The scope of delivery includes the Motoman welding robot (or robots), the platform, metal walls, a fume hood with outlets for ventilation and exhaust, a positioner or fixed table, start panel and CE-marking. The user-friendly design of the CS system gives operators their own separate working area in a bright workplace with curved sliding plexi doors and the required materials close at hand.

Connection of the CS system is easy, simply plug in the main power to the power distribution box located on the back of the platform while internal connection to the robot controller and interior lighting are already in place. In addition to the outlet for the welding power source the power distribution box also has extra sockets for 230 VAC and 400 VAC that can be used for other equipment, while sockets for connecting pressurised air are located nearby.

The extensive ArcWorld range now covers nearly all options of robotic welding applications, such as; MIG, TIG, Plasma, spot and laser welding. The corresponding drive and control technology, along with turnkey automated welding systems, from standard cells to more complex customised systems combined with market leading expertise, underpins the success of the Motoman ArcWorld range of robotic welding systems.

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