IEN: How are MH vendors addressing demands for Custom Off-the-Shelf (COTS) products and systems?
Johnson: This is a great question for a robot company since robots are basically Custom Off-the-Shelf products. Designed as flexible automation, they need only a gripper and a program to start performing productive work. The robots are available in a complete range of payloads and reaches. FANUC Robotics even has 5 versions of 4 axes robots (most robots use 6 axes) for those applications where the part to be handled stays in an orientation parallel to the ground. Our V-500iA/2DV vision product comes as a COTS software product that runs on a standard PC. When you provide vision to a "blind" robot it allows the robot to react to parts that are "loosely" presented to the robot, for example on a pallet or on a belt conveyor. This allows the robot to adapt to an imperfect world to either allow new type applications to be possible to be robot handled or to allow the system cost to be reduced. For example, a system using accurate fixtures to present the part to the robot can be replaced with a less expensive belt conveyor and vision. Since the vision software is priced under $6,000 (without camera or PC), it can significantly reduce the system cost.
IEN: What are some applications of remote material handling and simulation?
Johnson: FANUC Robotics sells a popular simulation software package called ROBOGUIDE. Previously, simulation software was priced in the $30,000 to 45,000 price range. Priced under $10,000, ROBOGUIDE proves to be a valuable PC software tool for checking the reach study required by the robot, evaluating the cycle time that can be met, and providing output movie files that can be used to explain the system concept to management. It is programmed in the same language as the FANUC robot and allows programs to be downloaded from the PC to run on the robot. This tool allows for engineers to concept and prepare for the robot system. It also speeds the time required to commission the system once the capital equipment arrives.
IEN: Can you provide some examples of increasing intelligence in traditional MH equipment and components (lift-trucks, conveyors, containers, cranes, etc.)?
Johnson: One of the most interesting innovations in this area is the use of the robot as a lift truck. FANUC Robotics has a product called the top loader, which couples an articulated robot with an overhead rail to greatly increased the area that can be served by the robot. We have recently sold a system that uses a fork gripper on this style robot to unload product from a truck. Since the containers are only loosely located, the system uses the V-500iA/3DL vision to find the product in 3D space. The robot can then adapt the taught path to compensate for the actual part position to pick the part and unload the truck. This type system can offer an attractive alternative to unloading with fork trucks for those assembly facilities that make extensive use of their truck wells. For this system to work it does requires automation in the truck to index the next layer of product to be unloaded once the robot completes a layer.