Flexible Parts Feeding and Assembly
January 1, 2017
Calvary Robotics has selected Stäubli Robotics as its partner for its Flexible Feeding / Sorting Module. Tasks will include picking, placing and inspecting bulk fed parts with the module.
"Calvary Robotics selected Stäubli Robotics on this platform based upon the quality, speed, reliability and seamless integration of its robots to the Cognex vision system and conveyor tracking functionality," said a Calvary Robotics spokesperson. "In addition, the support provided in the development and debugging of the systems was paramount in the success of the product and implementation into a production environment. The robots performed flawlessly, contributing to the high uptime, throughput and reliability of the production systems."
The Calvary Robotics Flexible Feeding / Sorting Module features a bulk storage hopper that deposits randomly grouped and layered bulk parts on demand to a secondary belt feeder. During transport, the parts pass through both active and passive features that reduce bulk parts to a single layer consisting of separated, randomly positioned/oriented individual parts. The precision vision system that is incorporated into the platform determines the viability of parts for successful picking. Using Calvary Robotics vision algorithms, the vision system then identifies and records location relative to conveyor position and orientation of individual parts, which enables acquisition via the robot. The Flexible Feeding Module enables a high percentage of parts to be presented to the robot for picking. Any parts not deemed viable to acquire are then returned to the secondary belt for reuse.
Robot Based Picking and Placing
The relative position and orientation of identified parts is communicated to the robot. The robot then calculates the most efficient order to pick parts. Using seamlessly integrated line tracking the robot is able to pick parts while they are continuously moving on the feeder belt. The robot picks the identified parts and loads them to assembly fixtures which are located on the modular walking beam transfer system included within the module. A secondary vision system is included to verify that the assembly is correct following placement. Programs are selected via the intuitive and user friendly software interface which is included with the system. This module allows for multiple part variants to be fed through the same feeder with minimal or no changeover when running the next part variant.
Flexible Manufacturing Platform
As an alternative for those parts that do not have suitable features for the flexible part feeding method, the feed module can be re-configured to accept feed systems that are more dedicated in nature. This includes some of the most reliable industry standard feeders such as vibratory feeder bowls, step feeder systems or matrix tray feeders. This is made possible through flexibility built into the platform, which is comprised of multiple standard feed modules that feature plug & play modularity as well as a pass through rapid transport system to transfer parts between modules. Simple mechanical interface points allow quick and easy scaling of interconnected modules for process changes or simple redeployment. A dedicated master control module is required for distributed process control of each flex pick module in the system. This module features the PLC and HMI for operator interface. A dedicated unload module is also utilized for unloading of parts and/or bulk part packaging. The flexible feeding technology is dependent upon the part geometry for orientation purposes and applications need to be assessed on a case by case basis.
Customer benefits include:
- Increased productivity
- Short cycle times
- Compliance with high quality standards
- Ease of service and maintainability
- Low energy consumption
- Compact space requirement
- Modular cell design
- Quick change robot EOAT
- Fully automatic assembly
- Integrated vision and inspection.
For more information contact:
Calvary Robotics
855 Publishers Parkway
Webster, NY 14580
585-347-6127
info@calvauto.com
www.calvaryrobotics.com
Staubli Corporation
201 Parkway West
Hillside Park P.O. Box 189
Duncan, SC 29334
864-433-1980
www.staubli.us
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