To integrate robots into the overall automation process, there is no longer a need for specialized programming devices, as the application module can achieve motion design through simple parameter settings.
The growing trend towards product personalization has led to smaller batch sizes in manufacturing, necessitating more flexible production equipment. This has given rise to robots, whose participation in industrial manufacturing has increased dramatically as they are no longer confined to rigid processes.
The specific kinematic principle used is not important; the key is to complete multi-dimensional movements within a single space. This can be achieved through linear connections in a gantry system or non-linear connections like those used in a triangular robot. Given the wide range of applications for robots in the manufacturing industry, machine manufacturers need flexible technologies that can easily adapt to various task requirements.
By using robotic modules, even complex pick-and-place movements become as simple as single-axis movements.
Lenze has developed a pre-programmed software module for the resurgence of driving tasks: the application software Toolbox Fast.
It includes fully ready-made robotic solutions that allow for easy integration of robots into overall automation processes and control of their movement. For example, it offers technical modules for pick-and-place applications and coordinate transformation modules for various motions.
The robot module integrates a high-efficiency robot core with 6 degrees of freedom. In path planning, the highest degree of freedom is ensured by PLC-Open Part 4. At the same time, the pick-up and put-down movements can be completed very easily by simply adjusting the parameters, without the need for professional robot knowledge.
Depicting client-specific movements without requiring knowledge of robotics
Lenze divides its robotics technology into motion and path planning. The company collaborates with universities, integrating the robot's geometric calculations and motion models into the core using a universal coordinate transformation method. This allows for the rapid and efficient depiction of client-specific motions even without prior knowledge of the robot. In other words, trajectory planning is not limited by kinematics; the relationship between the motion model and the moving components provides the robot with motion instructions. This offers a significant advantage: if the motion changes, the entire program is retained; users only need to set parameters, without reprogramming.
The robot core supports traditional motion commands: linear, circular, curved, and point-to-point. These PLC-Open Part 4 motion commands can be used in the IEC 61131 programming environment. Through PLC-Open's "Buffer-Mode" and "Blending" functions, movements such as "looking forward" and smooth motion can be achieved. To meet these specific requirements for robots, the PLC-Open command package extends some special functions.
Robotic modules with a perfect robotic core enable people to easily achieve coordinated multi-axis movements.
Lenze provides integrated motion models for Delta2, Delta3, Knickarm, Scara, and various types of gantry robots. In addition to up to six main axes, secondary axes can be controlled, easily handling speed-limited processes such as glue application and welding head guidance. Various TCP (tool center point) tools are also compatible. Synchronization between the robot and conveyor belts, such as grasping moving objects, can also be achieved.
Therefore, the process module and motion module contain all the elements necessary to complete the task. Users only need to know what the motion task is, not how the robot is programmed. Other advantages include: once a different motion is adopted, aside from the mechanical integration, only the corresponding motion module needs to be replaced and the necessary mechanical parameters set.
Standard technical models simplify engineering
This approach supports machine modularity, reducing task complexity by breaking down tasks into multiple parts. Standardized technical modules allow for reliable disassembly and reuse of robot modules, ultimately simplifying engineering, improving software reusability and quality, and reducing testing costs. Lenze Fast's included application templates facilitate modularization in the control domain. Through the template's OMAC variables, packaging equipment manufacturers can implement their own applications according to the Pack-ML standard, and customer-specific program components can be easily integrated, just like process modules.
With Lenze Fast components, robot applications can be used in the controller through simple parameter settings without programming. Since the controller can also control other axes of the equipment and production processes, complex interface programming is eliminated, making the engineering process simpler and more versatile, and significantly reducing training, programming, pilot production, and testing. Just how simple this is can be seen with the development tool PLC Designer, which also makes testing visible.
For example, for pick-and-place movements, customers only need to select the motion module, call the process module in the program, and set the parameters, and then the pick-and-place movement can begin. In this way, complex pick-and-place movements become as simple as single-axis movements used for positioning.
With the help of pre-designed software modules, machine manufacturers can integrate various motions to complete operational tasks.
In actual production, it remains common for equipment manufacturers to purchase finished moving parts and then program them themselves or use entirely proprietary robot solutions, integrating them into their equipment. When using a complete robot, robot control must be integrated, addressing all issues including software versatility, communication, and engineering tools. Conversely, when using free-moving parts, overall programming is necessary. Lenze addresses this by extending its application software Toolbox Fast, treating control and motion functions as a unified whole, merging traditional motion control and robot control in terms of hardware.
In the coming years, robotics will enter the realm of specialized and complex mechanical solutions that have been preserved to this day, where even the most demanding tasks can be automated through multiple movements by standard robots.
Machines become more flexible, while engineering costs in the mechanical, electronic, and especially software fields decrease. People's jobs are simply to understand the robot's specific movements, without needing to program the robot.
