The X-365 is a modular, high-performance gantry platform that combines large travel ranges with nanometre sensor resolution. Designed to bridge the gap between classic XY stages and full robotic systems, the X-365 delivers smooth, coordinated motion over travel ranges exceeding typical precision XY systems while maintaining excellent planar accuracy and repeatability. Its rigid mechanical design and integrated linear encoder feedback provide the positional stability needed for precise pick-and-place, multi-field inspection and patterning tasks.

“With the X-365, system builders and integrators gain a flexible Cartesian robot backbone that supports both high-speed motion and precision positioning,” said a spokesperson for PI. “This gantry system allows users to scale performance without sacrificing the sub-micron control needed for advanced manufacturing and inspection processes.”

Key features of the X-365 include:

• High load capacity and large travel: Engineered to support tooling, and payloads across extended XY travel ranges.
• Nanometre-class position feedback: Integrated linear encoders and optimized mechanics deliver outstanding precision and repeatability. The gantry system features precision recirculating ball bearing guides for superior stiffness and flatness, along with thermally decoupled components for enhanced performance stability.
• Modular and customisable: Easily configured as a dual-axis gantry and adapted, with options for additional vertical or rotary axes. Travel ranges from 200 x 200 mm to 600 x 800 mm.
• Seamless controller integration: Fully compatible with PI’s EtherCat-based advanced motion control platforms, enabling coordinated motion profiles, automated multi-axis sequences, integration of third-party equipment, enabling precision laser control for high throughput applications.

Industries and applications served

The X-365 gantry is ideal for precision assembly, laser machining, additive manufacturing, wafer inspection, optical alignment, 3D printing, electronics manufacturing, imaging, medical engineering, and other applications where high performance and reliability are paramount.

With decades of precision engineering experience, PI continues to expand its Cartesian and gantry portfolio to meet the evolving needs of industrial automation and scientific research.

The long-stroke type features a maximum stroke of 3,000 mm, a maximum payload of 200kg, and a repeatability of ±0.01 mm, delivering both high-precision long-stroke capability and high payloads. Equipped with Yamaha Robotics’ proprietary Optimal Support Mechanism (patented), it suppresses speed reduction caused by critical-speed and enables operation at a maximum speed of 2,400 mm/sec.

The timing belt drive type achieves a maximum stroke of 4,000 mm and a maximum speed of 3,750 mm/sec, representing the highest speed in Yamaha’s history, enabling high-speed, long-distance transfer between production processes.

The low-profile type contributes to overall equipment downsizing by reducing total height, while its slimmer design still maintains high rigidity and ensures excellent accuracy. All models are equipped as standard with shutters that cover the guides, ball screws, and belts to prevent grease dispersion and foreign-matter contamination, allowing use in today’s manufacturing environments requiring high cleanliness and dry conditions, such as semiconductor and EV battery production.

With products becoming increasingly compact, high-density, multifunctional and diverse, product life cycles are also shortening at a rapid pace. In response, manufacturing sites are facing greater demand for multi-variety, variable-volume production, along with the need for higher equipment efficiency and shorter delivery times. In particular, the global increase in automotive battery production has led to a growing need for transfer systems that can handle copper material restrictions, low dew-point (dry) environments, low dust generation, and anti-rust performance.

To meet these evolving needs, Yamaha Motor launched the Robonity series in May 2019 – a versatile line-up that allows users to choose between motorless single-axis actuators and single-axis robots, suitable for a wide range of applications from positioning to material transfer. Since its launch, Yamaha has continuously expanded the line-up, and the series is now widely used in the automotive components, electrical and electronic, and consumer goods industries, among others.

The newly added long-stroke, timing belt drive, and low-profile types are all compatible with clean manufacturing environments with high air purity. With these additions, the Robonity series now offers 54 models, enabling customers to select the most optimal specifications from an extensive line-up.

Roose Automation wanted to give its robot arm the freedom to move across multiple chocolate dispensers inside a compact vending unit. A standard 6-axis robot couldn’t cover the full range and integrating a linear axis often means weeks of additional programming.

With the ready-to-install 7th axis from igus, a robot’s working range is quadrupled, and it also connects directly to its controller with the company’s “plug-to-program” interface.

“In projects like ChocoMatic, it’s about simplicity,” says Adam Sanjurgo, Automation Product Manager at igus. “You install it, the controller recognises it, and it just works.”

The igus axis forms the backbone of the ChocoMatic system. Mounted beneath the robot, it allows precise horizontal movement over multiple trays, powered by a toothed-belt drive that delivers up to 0.6 m/s speed and ±0.3 mm positioning accuracy.

With the plug-to-program system, Roose Automation integrated the axis directly into the robot’s control software. No extra coding, no complex interface design.

The results have been impressive: weeks saved in development time; thousands of pounds saved in programming costs; and flawless operation and increased productivity.

The success of ChocoMatic goes beyond chocolate. It shows how smart, modular automation can unlock new applications for SMEs. The igus linear axis lets a single robot do more – serving multiple machines, workstations or products, all without sacrificing precision or control.

Each igus 7th axis supports robots up to 55 kg, runs on a lightweight aluminium rail up to 6 metres long, and includes lubrication-free polymer bushings and e-chains from igus for cable protection.

Now compatible with the latest robot models including Universal Robots UR 20, UR 30 and Fanuc CRX, the 7th axis is making long-reach automation faster and easier for companies everywhere.

“The ChocoMatic shows how our plug-to-program technology can help any company, not just in manufacturing.” says Sanjurgo. “Expanding a robot’s range used to mean extra engineering. Now it’s as easy as plug, play and produce.”

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The igus product portfolio includes flexible cables, robotic components, motor control and sensors, all aimed at improving technology, reducing costs and enhancing durability in a wide range of industries, including machine tooling, automotive manufacturing, food and beverage packing, medical and lab equipment and smart agriculture.

The igus ReBeL (Robotic embedded-BDLC and electronics Link) cobots, now available from Mouser, are cost-effective and lightweight robotic arms featuring up to six degrees of freedom. These cobots are compact and lightweight in design, making them suitable for assembly tasks, quality inspection tasks, and service areas. Integrated sensors, cameras, and advanced software ensure safety, flexibility, and adaptability in a wide range of environments.

The igus Gantry robots, also known as cartesian or linear robots, feature two base X-axes, a Y-axis, and an optional Z-axis. These robotic devices are ideal for applications where high precision is needed and where a task requires a repetitive motion, such as pick and place, sorting, labelling, and measurement. These Gantry robots feature self-lubricating plastic liners that slide instead of rolling, making them much more efficient than similar devices that use recirculating ball bearings. These robots are lightweight, clean, quiet, corrosion-resistant, and maintenance-free.

The drylin Delta robots are designed with linear actuators, featuring highly engineered, self-lubricating sliding plastic liners. These liners make them lightweight, quiet, cost-effective, and low-maintenance. The Delta robots are suitable for low-cost automation applications such as belt transfer stations, sorting systems, small parts handling, and fast positioning machines. The Delta robots offer an accuracy of +/-0.5 mm.

The igus e-chain cable carriers guide and protect energy, data, and signal cables in challenging environments. The e-chain cable carriers reduce downtime and increase the service life of cables. These cable carriers feature a low-weight, modular, strong design, smooth contours, and are easy to install. The e-chain carriers are well-suited for cable management in various settings, including industrial, energy, medical, construction, and stage and theatre.

Mouser will also be offering igus’ chainflex cables, which are designed to deliver unmatched reliability, durability, and performance in industrial motion applications. With over 1,300 cable types available to order, chainflex offers a comprehensive range for data, bus, hybrid, control, motor, servo, feedback, coaxial, fibre optic (FOC), robotics, and special applications.

This collaboration makes the Thomson Movotrak CTU the first cobot 7th axis technology that ABB Robotics has certified for use in its partner ecosystem.

“Until now, anyone wanting to use a single, plug-and-play ABB cobot on multiple workstations faced what could be days of programming and communications challenges. As part of the ABB Robotics partner ecosystem, we have preconfigured our Movotrak CTU, ensuring rapid deployment with ABB cobots right out of the box. Integrators, distributors, and end-users can now invest more time using the 7th axis to solve productivity problems than dealing with complex integration details,” said Kevin Zaba, EVP and President, Automation and Motion Control segment of Regal Rexnord.

Extended Operating Range: The Movotrak CTU is the first collaborative 7th axis, extending the traditional cobot operating range up to 10 metres.

Flexible Mounting Options: Ability to move from one workstation to another along a rail that is secured either to the floor, wall, or ceiling.

Collision Detection: First 7th axis solution with collision detection, stopping the cobot when it encounters an obstacle.

Increased Productivity: Less downtime with easier training and installation featuring 7th axis Freedrive mode.

Single-Source, Fully Integrated Solution: Thomson linear units are integrated with other Regal Rexnord components, including Boston Gear gearheads, Huco couplings, and Kollmorgen motors and software for a complete, high-level assembly with one part number.

“This collaboration with ABB Robotics is a great example of how our differentiated Regal Rexnord technologies can be integrated into high-impact, customer-ready solutions,” said Louis Pinkham, CEO of Regal Rexnord. “By combining the technical expertise of our Thomson, Kollmorgen, Boston Gear, and Huco brands into a seamless, 7th axis system available for the ABB Robotics partner ecosystem, we’re making it easier for customers to unlock greater productivity and flexibility in their automation strategies. It also reflects our ongoing commitment to innovation and delivering value through system-level thinking.”

The ABB Robotics Ecosystem

ABB partners develop and provide packages consisting of pre-engineered accessories and software that are compatible and easily integrated with ABB’s complete portfolio of robotic solutions. As fully integrated, ready-to-use solutions, the packages enable both end users and systems integrators to reduce time and effort in setting up robots for new applications.

Regal Rexnord’s participation in the ABB partner ecosystem involves changes to mounting hardware, development of a specialised plug-and-play wiring harness, and programming to interface with the ABB software platform and engineering environment, including an ABB Web App, Wizard and RAPID Module Code programming tools. Through the integration, certified ABB robotic application developers will be able to access the Thomson configuration tools directly on the ABB FlexPendant user interface.

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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Visitors will also see how LC Automation’s kit integrates seamlessly with Mitsubishi, Weidmuller and Lutze equipment. Plus, don’t miss a live demo of SICK’s nanoScan3 – the compact replacement for older S3000 safety scanners.

Whether you’re planning your next machine or upgrading existing systems, come and see what’s possible with LC Automation on Stand 82.

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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A working Rexroth Cartesian Gantry demonstration will be on the stand along with various linear actuators and linear motion components, such as profile rail guides and slides.

As an authorised distributor and stockist for several world-leading linear motion and actuation manufacturers, including Rexroth, THK and Ewellix, ACORN can offer solutions that best suit an application, rather than a solution that suits the manufacturer.

ACORN’s experienced technical experts can work with you to gain a proper understanding of your requirements. They will then advise on the specification and sizing of components to provide the most appropriate product for an application.

In addition to its specialist linear capabilities, ACORN is also one of the UK’s largest suppliers of rotary bearings, couplings and power transmission products. Each division has highly experienced product managers focused on its range of products. On-site visits are available should you wish.

For machine builders and systems integrators, Kyrus brings to the table a range of automation products and guarding solutions with both longevity and modularity in mind. Companies are always growing and changing, and Kyrus aims to offer solutions that will adapt and grow at the same pace.

At the core of what Kyrus offers is in-house designed extrusions for its range of linear tracks, gantries and machine guarding, all designed specifically for machine building and automation solutions. From standard ranges to bespoke customer requirements, Kyrus products can be easily integrated into a project of any size.