IEN: How are manufacturers using existing technologies in new ways?
Motley: Fanuc Robotics sees the emergence of material removal as a new application segment for robotic automation. We have seen some new applications in deflashing, deburring, polish, etc. Several different robots can be used in these applications.
The superior rigidity and payload of the F-200i makes it well suited for the rigors of heavy duty deflashing, drilling, and hole cutting. The F-200i is capable of significantly higher feed rates versus a serial link robot, with up to 200mm/sec. for deflashing of 3/8 in web aluminum castings and up to 35mm/sec for hole cutting of 3mm thick cold rolled sheet. The F-200i also has increased accuracy due to less robot deflection, increased tool life due to less vibration and tool chatter, and can include semiautomatic or fully automatic tool change
IEN: What are the major concerns facing robotics in the next few years?
Motley: Intense pricing pressure from auto OEM and ripple effect through Tier 1, 2, etc.
IEN: What innovations are in store for users (e.g. mobile robots, intelligent robots, wireless robots)?
Motley: Some innovations are already being put into the manufacturing environment, such as the intelligent robot, the I-21i. This robot makes complex assembly possible. The I-21i robot is considered to be the first industrial, "intelligent," six-axis robot that can perform skilled operations because it has vision and force sensing capabilities. The Fanuc Robot I-21i makes it possible to automate some of the most demanding mechanical assembly processes.
The Fanuc Robot I-21i has sensory controls using a three-dimensional (3-D) visual sensor and a six-axis force sensor. The 3-D visual sensor can locate randomly positioned parts in any orientation. It can determine the location and orientation of parts, greatly reducing dependence on expensive part fixturing. The intelligent robot allows for smaller and simpler systems.
The integral force sensor gives the robot gripper a precise sense of insertion so it can assemble precise mechanical parts. When combined with a six-axis, articulated robot, it can be used to insert parts in horizontal, diagonal, and vertical directions. Currently available assembly robots can only insert parts in the vertical direction.
In addition, web connectivity for robots is available with Fanuc Robotics'' new iPendant, a new color graphic user interface device to the Fanuc System R-J3i Model B Controller that is based on Internet technology. The pendant includes an integrated Internet web browser allowing critical support information to be accessed right from the robot. Users can access corporate websites, Fanuc electronic documentation/manuals, and advanced diagnostic and part information. It provides a single point of access to web-based information right in the palm of the user''s hand.
IEN: How are software and equipment being improved?
Motley: We are riding the microprocessor wave -- more computing power equals higher performance, more features. All of these have helped make robotics easier to use for our customers.
FANUC Robotics recently introduced a new offline simulation palletizing package called PalletPro. This visual 3-D simulation package aims to allow users to set up a palletizing cell, verify system throughput, and verify reach and interference zones.
Users can create pallet work cells and define palletizing parameters by creating unit loads with PalletTool PC and a work cell layout in 3-D. Customers can obtain the accurate throughput of the work cell because PalletPro is running with Fanuc Robotics'' PalletTool software on a virtual robot controller. PalletPro also allows users to create a 3-D world visualization of the palletizing process by creating animation video files of the "virtual work cell."
IEN: How is robotics being used in e-manufacturing?
Motley: Fanuc Robotics sees networking and communications technology as an emerging reality. Manufacturers can use these technologies as a real-time window into the factory floor and equipment.
Manufacturers benefit from the networking options in several ways. By networking, companies can gather production data and monitor operations to track system critical information. Users can view robot-specific data in a browser or through custom interfaces written with Fanuc Robotics'' advanced programming tools. The controller gathers information such as alarms, I/O states, and program variables to publish them to simple web pages. User programs can be written to gather process-specific information to be included in web pages that are served over the network using the robot''s own web server.
Application-specific data can also be retrieved from the robot across the network and used in programs running on remote PCs. These are implemented using application program interfaces (APIs) that Fanuc Robotics offers for developing PC applications that communicate with the robot. Companies can also view live robot Teach Pendant screens on a remote computer terminal. These screens are very useful when troubleshooting remotely.
IEN: How is the drive toward lean manufacturing impacting this sector?
Motley: Lean manufacturing favors robotics because they are scaleable, flexible, re-deployable and have a low cost of changeover and retooling.