FANUC America Demonstrates Spot Welding with its Gakushu (Learning) Robots at IMTS 2014

ROCHESTER HILLS, Mich., Sept. 8, 2014 – FANUC America Corporation demonstrates spot welding with the intelligent R-1000iA and R-2000iC Gakushu (Learning) robots during IMTS 2014, Sept. 8-13, at McCormick Place, Chicago, booth #S-8919.

At the show, two Gakushu (Learning) robots (a new R-2000iC/165 and an R-1000iA/100F) positioned on the right side of a vehicle will compete with two standard robots positioned on the left side of the vehicle.  Both pairs of robots will execute the same spot welding program on opposite sides of the vehicle.  The Gakushu (Learning) robots show a significant improvement in cycle time compared to the standard robots.

“We are showcasing the new wireless LVC (Learning Vibration Control),” said Mike Webb, product manager, FANUC America.  This makes it easier and quicker to teach the robots.” 

The demonstration also highlights FANUC’s intelligent interference check which automatically determines shared workspaces to avoid collisions.  “This is extremely valuable and cost-effective in high-density cells where multiple robots work together,” added Webb. 

The Gakushu (Learning) Robot uses FANUC’s patented software to improve robot performance by learning the characteristics of programmed paths and then speeding them up while maintaining the programmed paths and smoothing motion. Motion cycle time is reduced by up to 15% with the added benefit of smoother overall motion. 

“The Gakushu (Learning) Robot maximizes robot speed and reduces robot cycle time while smoothing motion and maintaining the taught path,” added Webb. “This product is ideal for manufacturers looking to increase production.  Whether it’s eliminating a system bottleneck, or increasing overall line rate, the Gakushu (Learning) Robot can help without large investments in capital equipment.”

Intelligent R-2000iC/165F Robot  

The new R-2000iC/165F is part of a family of industrial robots, including pedestal and rack mount versions with a variety of payloads and reaches.  The R-2000iC/165F offers a more compact design than the previous model, and modular cable assembly which minimizes interference with system equipment and allows the robot to operate in small workspaces. 

R-2000iC/165F - key features and benefits

• R-2000iC/165F robot offers a 165 kg payload and 2.65 meter reach.
• Fast and accurate with FANUC’s world-renowned motion control technology.
• Multiple mounting options including floor, rack, angle and ceiling.
• Optional Solution Arm dressout package with internal cable routing for spot welding processes.
• IP67 rated wrist allows operation in wet conditions.
• Supports a wide range of intelligent functions including iRVision and Force Sensing.

Intelligent R-1000iA Robot 

The R-1000iA robot offers three models.  The R-1000iA/100F has a 100kg payload, and the R-1000iA/80F and 5-axis R-1000iA/80H have an 80kg payload.  The R-1000iA features a slim design, allowing customers to reduce the overall size of their automation system by using more robots in each work cell, or making work cells with a single robot significantly smaller.  The narrow footprint of the R-1000iA also allows for easy access to adjacent robots, fixtures and work pieces. The R-1000iA can be floor or invert mounted, and has a large work envelope. 

“The R-1000iA is also more energy efficient than robots with larger payloads,” added Webb. “Manufacturers using fewer or smaller work cells requiring less conveyance equipment, sensors, and control panels will realize an additional energy advantage provided by smaller automation systems.  This equates to a greener facility using less energy.” 

R-1000iA Features and Benefits

• Very small footprint reduces size of automation system.
• High-density installations allow work to be completed in fewer stations.
• Single-robot work cells can be designed to fit in tight spaces.
• High-speed operation minimizes robot cycle times.
• Simple serial-link configuration with large operating envelope (including rear and downward side).
• Upright or invert mounting accommodates a wide range of work areas without a reduction in payload.
• Strong wrist load ratings support the latest compact servo weld guns.
• IP67 rated wrist allows operation in wet conditions.
• Right sized for 80kg or 100kg applications reduces energy usage.
• Optional Solution Arm dressout package with internal cable routing for spot welding processes.

FANUC iRVision 

FANUC iRVision is a truly integrated, plug-and-go vision system that runs on the standard CPU of every FANUC R-30iB controller without any additional hardware.  A single source solution developed and supported by FANUC, iRVision offers easy setup and operation for factory environments requiring 2D and 3D guidance, error proofing, visual tracking, and quality control – all with FANUC’s world-renowned reliability.

Next Generation R-30iB Controller

The FANUC R-30iB Controller uses high-performance hardware and the latest advances in network communications, integrated iRVision, and motion control functions.  The R-30iB Controller features FANUC’s exclusive and easy-to-use iPendant with 4D graphics.  The iPendant displays process information and the actual process path directly on the iPendant screen, enabling easier setup and troubleshooting. 

Based on the latest FANUC Series 30iB CNC Controller, the R-30iB Robot Controller is compact, providing customers a significant space savings.  The R-30iB Controller is also energy efficient, requiring less power consumption than previous models, and available with an optional power regeneration feature.

Dual Check Safety (DCS) Speed and Position Check Software

Prior to the application of safety rated robot software, all safeguarding of the robot needed to be external, and required a safety rated limit switch or cam system, safety rated area scanners, or other devices to limit robot travel or enhance protection.  DCS safety rated robot software allows the safety design of the robot system to use the robot itself for some of the safety functions. 

The most significant benefit of DCS Speed and Position Check is in applications where the travel of the robot needs to be restricted due to floor space or process limits that are less than the full reach of the robot.  Restricting the robot motion in Cartesian space means the robot can be restrained to exactly the area in which it works; something that is not possible with the current systems that limit robot motion externally using limit switches.

“By moving some of the safety functions to within the robot, customers will realize significant savings in floor space, flexibility in system layout, reduced hardware costs, and improved reliability,” said Claude Dinsmoor, general manager, material handling segment, FANUC America.

In addition, safe "zones" can be enabled and disabled from an external source such as a safety PLC (based on the cell design). Designing a system with multiple zones and appropriate guarding means an operator can safely enter and leave the workspace of the robot. 

“This streamlines the design of robot cells because it prevents the robot from entering the load area when an operator is present,” added Dinsmoor. This type of application is possible with existing technology, but it is typically difficult to setup, expensive to implement, and requires more floor space than a system using DCS.”

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About FANUC America Corporation

FANUC America Corporation is a subsidiary of FANUC CORPORATION in Japan and provides industry-leading CNC systems, robotics, and ROBOMACHINEs. FANUC’s innovative technologies help manufacturers maximize productivity, reliability, and profitability. Headquartered in Rochester Hills, Michigan, FANUC America has facilities throughout North and South America. Learn more at www.fanucamerica.com or explore collaborative robots at crx.fanucamerica.com.

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