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INNOVATION DRIVES FRESH APPROACH PAGE 6 FLEXIBLE PACKERS REMOVE THE STRAIN PAGE 16 ROBOTS BOOST CHEESE PRODUCTIVITY PAGE 20

FOOD

SECTOR ROBOTICS REVIEW 2010

Robots cut lettuce labour issues Page 10


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In the yellow world of FANUC Robotics the focus is on speeding up your business, improving your products and reducing your costs. Discover the world’s most varied range of robots which provides unbeatable 99.99% reliability. Strengthen your competitive advantage with intelligent automation solutions – we have everything you need: Smart. Strong. Yellow.

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FANUC Robotics – NO. 1 IN FACTORY AUTOMATION AND ROBOTS www.fanucrobotics.lu


E D I TO R I A L Welcome to FANUC Robotics Food Sector Robotics Review Welcome to this special issue of FOOD Sector Robotics Review. FANUC Robotics has been supplying robots to manufacturing industry since 1982 and many of these installations have been in the food industry. Introduced in this issue is a new robot designed specifically to meet the demands of the food sector. The FANUC M430iA represents a landmark for FANUC Robotics and promises to make a truly reliable and cost effective solution to any business that picks and packs food. Flexibility continues to be a key requirement of the industry. From the Arctic Circle to the Mediterranean we report on leading food companies to give a flavour of typical solutions robots are providing – what really stands out with all users is that once a robot is installed, there quickly follows plans to install further systems. Increasingly we hear from our customers in the food sector that they see robots as an essential component to integrate into their picking, packing and palletising lines. Robots are penetrating the domain dominated by dedicated ‘hard automation’. Unreliability and inflexibility often associated with specially designed ‘hard automation’ are both totally unacceptable in today’s highly competitive environment. Also featured in our reports is the close working partnership we have established with system integrators. Food industry expertise is essential for both support and integration and these skills are in place to help FANUC Robotics’ customers throughout Europe. Finally we’re always happy to receive feedback from the food industry as this is the only way we can truly continue to develop and deliver our class leading, best value products. I personally welcome any comments from readers and hope you find this issue of interest. Olaf Gehrels

CONTENT M-430iA Smooth operator ready to set the pace

Fleury Michon Innovation drives fresh approach at Fleury Michon

El Dulze Robots cut lettuce labour issues

MS Selfoss Flexible packers remove the strain

KH de Jong Robots boost cheese productivity

04 06 10 16 20

Technical Specification FANUC FoodLine


04 M-430iA Smooth operator ready to set the pace


05 FANUC Robotics’ new food sector robot looks set to take automated picking and packing operations to a new level of flexibility and reliability. Renowned for their ultra high reliability and efficiency, FANUC Robotics products are working in some of the most aggressive environments possible throughout the World. Maintaining this reputation is critical to FANUC and developing a new robot for any industry is understandably a long process. The new FANUC Robotics M430iA has been designed specifically for the food industry and is the result of many years development. Using well proven FANUC mechanical and control technology the new robot has been designed from the ground up and resembles no other model in its wide range. Speed and easy wash down are the two obvious requirements for a food robot but of equal importance is the ability for it to keep working without attention for extended periods of time and for users not to need specialist skill to benefit from its capabilities. Looking at the robot it’s immediately apparent that its 5 axes (or optional 6 axes) arm is designed to be smooth – over its entire exterior surface there are no areas where contaminants can become trapped. The paint is a high gloss finish and is resistant to acids and alkaline materials. Washing down the robot with a hose is no problem as it is sealed to meet IP 67 standards and double seals on the major axes, joints one, two and three not only keep fluids out but ensure that its food grade grease stays within the durable casings. Joints four and five use nylon gears and do not require any lubrication. High speeds are achieved with the M430iA – carrying out the industry standard benchmark test where the arm moves up vertically 25mm, horizontally 300mm and then down 25mm, the new robot achieves 120 cycles per minute (cpm) with a 1kg payload and 100cpm with a 2 Kg payload. Using a conventional anthropomorphic configuration the arm generates very high torques to achieve these high speeds – joint one will rotate at 300º per second if required – to enable this FANUC has used two high speed heavy duty motors for each of the major axes using dual drive torque, tandem control technology.

R-30iA controller Making the M430iA’s precise movements possible is a new intelligent controller – the R-30iA controller. The new FANUC Robotics controller provides enhancements to performance, an increase in the number of robot arms it can control and a fully integrated vision control system. The R-30iA controller has improved vibration control which allows its motors to have shorter acceleration and deceleration times – essential for high speed food picking operations. Further control enhancements, including high performance constant path, help to speed up programming significantly. iRVision system Where vision is required the R-30iA controller helps reduce integration time and cost with its new integrated iRVision system. No additional hardware, other than a camera, is required to integrate vision with the new controller. The iRVision system manages all image processing on the robot controller and by direct connection to the FANUC web server provides intuitive setup information. A clear camera image and programming data is displayed on the controller teach pendant making it easier for installation engineers to access information. Control of up to 40 multiple axes is available with the R-30iA controller and when used in multi-arm mode one controller can control four arms and four auxiliary axis groups. A typical use would be a multi-robot picking application. Further reducing the additional control hardware common to any installation, the new controller is complete with its own Programmable Machine Controller (PMC). The PMC has an integrated monitor which allows the user to monitor the PMC ladder in a graphic display for all levels and sub programs that reside in the controller.

Designed to be base mounted to a machine or hung from a gantry, the arm is extremely compact with motors well clear of the operational area. The small ‘footprint’ occupied by the M430iA and its long 900 mm reach ensures a large work envelope that allows the possibility to position many operations within a small area.

FANUC R-30iA controller


06

Innovation drives fresh approach at Fleury Michon


07

FANUC M-410iB palletising

Appealing to the consumer in today’s ‘ready meal’ market is an increasing challenge for any manufacturer in the food sector – today’s non-stop lifestyles are fuelling a highly competitive growth market with many players. A market leader in France, Fleury Michon, is able to keep ahead of the followers by its continually innovative approach to its business and manufacturing processes. With operations across seven sites in France, three in the Vendee region, Fleury Michon employs in total 3,193 people producing fresh prepared meals, frozen meals and, as the number one producer in France, pork products including ham and sausages. It has a clear technological leadership in producing ‘35 days’ fresh meals as well as producing very fresh ‘8 days’ products. Along with successful initiatives, including twenty years of collaboration with top chef Joël Robuchon, Fleury Michon has developed innovative manufacturing processes to help maintain its lead. Along with a consistent objective to enhance working conditions, these innovative processes have also driven the implementation of automation at several sites. Ten robot systems are now operating at Fleury Michon sites all using FANUC Robotics products. “We installed our first robots in 2003 on end of line palletising applications,” explains Laurent Mailly, Fleury Michon’s Packaging and Process Equipment Development Manager, “Our philosophy then, as it now, was to keep applications simple. The first systems were implemented successfully and the employees became confident with their capability.”


08

FANUC M-410iB palletising

More complex systems are now under way at Fleury Michon but the emphasis is strictly to use robots only where they are justified. Laurent explains, “We don’t do ‘robotisation’ – we implement mechanisation – this means that although we don’t see robots as the panacea to all problems, we do see them as the solution to many applications that were previously solved by specially designed and dedicated equipment. “This approach allows us far more flexibility – our previous systems were dedicated to one size of product and to one operation. We now have the opportunity to programme robots for more than one product and if necessary for a completely different operation.” More robots will be integrated into Fleury Michon’s production and, as Laurent explains its still an open book, “We use FANUC Robotics currently throughout the company but that is on the basis that their products and services continue to fulfil our needs. The original decision to buy FANUC was made after an in depth survey of all suppliers. FANUC Robotics had the widest range to offer and we were impressed by its technical support. Commercially we have developed a strong relationship with FANUC; an essential element to continuing effective support. A food technology innovation developed by Fleury Michon requires that individually packaged items undergo a thermal process before being packaged into cartons. Three FANUC M410iB robots are involved in the installation avoiding a potential bottle neck in production output. Robot one handles a tray which has been collated with individual packages, total weight 37 kgs, and places the tray onto a stack. Two stacking areas are managed by the robot which continues loading trays onto the stack until it is ready to be conveyed to a collection point. Complete stacks of trays are removed manually and taken into the processing area.


09

“The implementation of robots into Fleury Michon has been a success. They have helped us to meet our production objectives and in particular our need to continually try to improve working conditions for Fleury Michon’s employees. We have a loyal workforce which is essential for us to maintain our very high quality levels.” Laurent Mailly

Robot two takes trays from complete stacks and positions them into a picking area where they are re-loaded onto the carton packing line. An additional FANUC M410iB is positioned between the two robot installations. This third robot is able to support either of the other two robots in cases of maintenance or increased production demands. “The implementation of robots into Fleury Michon has been a success,” continues Laurent. “They have helped us to meet our production objectives and in particular our need to continually try to improve working conditions for Fleury Michon’s employees. We have a loyal workforce which is essential for us to maintain our very high quality levels”. Finally when questioned if the robot installations have given a strong return on investment (ROI), Laurent concludes, “I wouldn’t single out a return on the robots alone – they are part of a much wider investment related to producing our products to a high standard, competitively and to produce what the end customer wants. Will we continue to invest in robots? Yes without any doubt – wherever they can be used to help us maintain our innovative approach and of course our market leadership.”

AT A G L A N C E • Market leader Fleury Michon maintains market leadership by innovation in product development and manufacturing processes • Uses ten FANUC Robots and keeps systems engineering simple • See robots as a solution to many applications where previously dedicated automation was used • Robots allow Fleury Michon more flexibility • Strong commercial relationships are essential for successful automation systems • Robots have helped Fleury Michon achieve production objectives and improve working conditions • Robots alone are not singled out to measure ROI – they are part of an overall investment in equipment, time and personnel


10 Robots cut lettuce labour issues Agriculture is big business in the Murcia region of Spain, climatic conditions and soil type allow the production of vast quantities of vegetables that are a major contributor to the Spanish economy. The agricultural industry in the region understands the importance of technology to maintain its competitive position in European markets and actively applies research and development to keep ahead. The value of technology has been ďŹ rmly grasped and implemented by El Dulze, a family run business that produces lettuce. Its ofďŹ ces and packaging plant are based in San Javier, Murcia. Investment by this company is very apparent – the new facility has an ultra modern look more familiar to the technology sector than to farming.


11

The implementation of technology in this plant is conďŹ rmed throughout the plant and in the packaging area the company now uses 68 FANUC robots. The entire packaging system was installed by an Alicante based FANUC Robotics systems integrator, IT Robotics. Lettuces taken straight from the ground are delivered to the plant in plastic containers stacked onto a euro pallet. These pallet stacks are located into a robot de-palletising area where a FANUC Robotics R2000iB removes one tray at a time and pours the tray contents onto the packaging line conveyor. The input conveyor orientates the lettuces so that they travel longitudinally onto the system conveyors. Positioned centrally on the input conveyor, and spaced individually, the lettuces are directed to the robot cutting stations.


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“Reducing the amount of people has made everything more hygienic and damage to the lettuces caused by handling is now minimal. The robots have reduced rejects from 20% to 5%.” José Sánchez, Managing Director of El Dulze

“We have a very good commercial relationship with FANUC and it was clear from first discussions that they had a good understanding of the size of the project. We already knew that FANUC made no compromise on quality and this care of quality was apparent at all stages from product supply to customer support.” Juan Martinez, General Manager of IT Robotics


13

Each robot, an LR Mate 200iB, performs the same task and sensors on the conveyor direct lettuces to the next available station. At this point the lettuce is orientated lengthwise on the conveyor but the root end is randomly positioned.

Lettuces that pass this final inspection are conveyed to an operator working at the robot station and these are placed into a plastic tray. Full trays are placed back onto the conveyor and sent to the packing area.

A vision system at this point is used to weigh and measure the diameter to assess the density of the lettuce. Lettuces falling outside the acceptable parameters are rejected at this point. The vision system also identifies the root position to the robot which then picks up the lettuce with a specially designed pneumatic gripper.

The plant is capable of packaging 550,000 lettuces and is currently operating at 400,000 per day. The system is a major investment for El Dulze but has been seen as an essential step for the business to take. José Sánchez, Managing Director of El Dulze, explains, “The need to invest wasn’t a difficult decision to make. Of course there are many reasons why this investment has been made but generally they all focus around delivering a consistently high quality product and keeping El Dulze competitive. This business has traditionally been labour intensive but today labour is increasingly unavailable.

The robot then positions the lettuce into a cutting machine where the root is removed. A second check is then made on the size of the lettuce as the robot holds the lettuce under the camera again.


14

FANUC R-2000iB loading lettuces to system

“This region has a major shortage of labour – many workers in the industry are immigrants but this hasn’t solved our problem. As minimal skill is needed we have a real problem with labour and turnover of these workers is high – they just seem to come and go.” By investing in automation to reduce labour shortage issues El Dulze has benefitted in many areas. The work force required to produce the current production levels manually would need to be 500 people, and would be a major management problem with many nationalities and languages involved– this has been reduced by 80% with 100 people producing this level of output. José explains further, “Reducing the amount of people has made everything more hygienic and damage to the lettuces caused by handling is now minimal. The robots have reduced rejects from 20% to 5%.” El Dulze aims to increase its overseas sales and as it takes the business to a higher level the overall investment has had an important impact. Visitors to El Dulze from major retailers are now exposed to a high level of investment and quality throughout the business and this commitment has had a major impact on gaining new business. The scale of the installation was a major factor in deciding which products to use in the project. Juan Martinez, General Manager of IT Robots explains, “The size of the project dictated that a close commercial relationship with the robot supplier was of major importance. We knew that FANUC Robotics produced a high quality, reliable product and that support would be available when required. Deciding which robots to use was a core decision as they are the heart of the system. Juan Martinez, continues, “We have a very good commercial relationship with FANUC and it was clear from first discussions that they had a good understanding of the size of the project. We already knew that FANUC made no compromise on quality and this care of quality was apparent at all stages from product supply to customer support.”


15

AT A G L A N C E • El Dulze is a leading producer of vegetables and currently processes 400,000 lettuces a day through its plant • It believes technology is important to maintain competitiveness in European agriculture markets • Has made a major investment to ensure its delivers a consistently high quality product • 68 FANUC Robotics robots have been installed to provide an operating capacity of 550,000 lettuces per day • Employee headcount is reduced by 80% by using robots and labour shortage issues are reduced • Robots have made operations more hygienic and also rejects have reduced from 20% to 5% • A good commercial relationship with the robot integrator is essential for successful installation


16

Flexible packers remove the strain

Iceland is a country of extremes which become immediately apparent to the first time visitor arriving by aircraft. It’s no surprise that Iceland was the practice ground for the Lunar landings of the last century. What is surprising is that even though cattle are not visible to the casual observer, the dairy industry is a contributor to Iceland’s exports. Mjólkursamsalan Selfoss (MS Selfoss) based in Selfoss, near to Reykjavik, is Iceland’s largest dairy products business and is part of the country’s dairy collective. It is also Iceland’s most automated dairy.


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Packaging cartons of Skyr into trays has now been fully automated at MS Selfoss by the integration of three FANUC Robotics LRMate 100iB – one on the end of each production line. Guðjón Einarsson, Technical Manager, MS Selfoss, explains, “Skyr is a traditional product unique to Iceland. It is similar to thick yoghurt with a soft and creamy consistency however, and one reason why export sales are so strong, it is totally fat free and is in fact a very soft cheese made from skimmed milk. Three main factors have made us automate the tray packing process. Firstly the need to increase output, high turnover of staff in the packing area and the repetitive nature of the job leading to potential strain injuries.” With only 300,000 Icelanders, 200,000 of which are employed in Reykjavik, there is close to zero unemployment levels. As filled and sealed product cartons travel down the end of line conveyor they are collated within two locating channels. At this point the robot picks up two cartons at a time and positions them into preformed locations within a packing tray. Each tray holds six cartons and when all locations are full the robot signals the system to remove the tray and a new tray is positioned into the robot area for the cycle to continue. “Before the robots were installed the workers on each line, four of them at that time, would take it in turns to transfer the cartons from conveyor to tray. This was a very repetitive task and couldn’t be undertaken for too long without missing cartons or becoming tired. The labour savings that have been made by implementing the robot systems are 1½ operators per line,” continued Guðjón. The flexibility offered by robots was a key decision point for MS Selfoss in the decision to select robots over conventional ‘dedicated’ automation. Many small ‘call off’ orders are required demanding total flexibility. With 30 different products and up to 10 product changes per line per day the ability to change programmes quickly is essential. The FANUC Robotics LR Mate intelligent control has the ability to hold all the programmes required for the Skyr product and only two different grippers are required for each system.


18 “Like any dairy environment there’s plenty of water used in the area for washdown purposes. This hasn’t been a problem at all as the robots are positioned within clear enclosures and are regularly wiped down with detergent.“ Thorkell Jonsson, Managing Director, Samey

FANUC LR Mate 100iB picking


19 “Before the robots were installed the workers on each line, four of them at that time, would take it in turns to transfer the cartons from conveyor to tray. This was a very repetitive task and couldn’t be undertaken for too long without missing cartons or becoming tired. The labour savings that have been made by implementing the robot systems are 1½ operators per line” Guðjón Einarsson, Technical Manager, MS Selfoss

The robot cells were engineered by Samey, an Icelandic based FANUC Robotics systems integrator. Samey engineered each system including control and conveyor, provided training on-site and support when needed. Thorkell Jonsson, Managing Director, Samey, comments, “These robots were installed over a three year period as required by production demand at MS and they have proved to be totally reliable. Like any dairy environment there’s plenty of water used in the area for washdown purposes. This hasn’t been a problem at all as the robots are positioned within clear enclosures and are regularly wiped down with detergent.”

The future for MS Selfoss is looking very positive with the quality and increasing popularity of its Skyr product reflected in year on year growth. Guðjón explains that the company is expanding and will continue to automate the plant. Palletising and further packing systems are proposed to maximise efficiency wherever possible. And finally for anyone wondering where the cattle are – they’re kept happily indoors for 8 to 9 months of the year and enjoy the Summer sunshine and grazing from June to August.

AT A G L A N C E • Mjólkursamsalan Selfoss (MS Selfoss) is Iceland’s largest dairy products business • Produces a traditional product unique to Iceland – Skyr - a totally fat free product made from skimmed milk • Skyr sales growth is strong and it is exported to many countries • Many small call off orders for Skyr require flexibility of the packaging line • Up to 30 different products and ten product changes per day per line • In the packing area MS Selfoss needed to increase output, overcome high staff turnover and avoid repetitive strain injury risks • Three FANUC Robotics LR Mate 100iB robots installed to meet production demands • Savings of 1½ operators per line • Enjoying growth in sales and planning further investment in end of line robots for packing and palletising operations


20 Robots boost cheese productivity


21

FANUC R-2000iB de-palletising cheeses from tray

Speeding up production is not something commonly associated with cheese manufacture – its very nature is that it should take time to mature for ultimate flavour. However, when production output is 350,000 tons per year, maximising the efficiency of packaging becomes a core issue. This is the case for Friesland Foods Cheese, one of Holland’s longest established producers of cheese.

KH de Jong, part of Friesland Foods Cheese, and one of four Friesland packaging facilities in Holland, use FANUC Robotics robots on three packaging lines. Over 350 tons of Edam, a traditional ball shape cheese produced in three sizes of 1.9 Kg, 1.7 KG or 0.9 KG, is packaged per week. Delivered to the facility on trays carried in transportation racks, the cheeses are allowed to mature before the packaging process begins. Each tray has capacity for 35 cheeses and ten trays are carried in each rack. When cheeses have reached the specified maturing stage the rack is delivered to a buffer area at the start of the packaging line. The buffer area has capacity for five full and five empty racks and automatically shuttles them into the de-palletising area. A FANUC Robotics R-2000iB takes one full tray from the rack and places it onto a fixture where it then uses seven vacuum cups to locate a complete line of cheeses. The cheeses are then accurately placed onto a conveyor with individual locations for each cheese. Empty trays are then returned to the rack and the process begins again.


22

FANUC M-710iC packing

Christiaan Hallers, Project Manager, KH de Jong, explains. “Dero, FANUC Robotic’s system partner based in Nieuw-Vennep, south of Amsterdam, was responsible for engineering the system and ensuring the racks are always positioned correctly for depalletising prior to being coated in the paraffin wax machine. This stage of the process relies on several intelligent features of the FANUC Robotics controller to ensure effective operation. Collision detection is very important when removing the tray from the rack. As the racks are used to transport the cheeses from factory to factory they can get damaged and we need to detect any indication of a stuck tray. Bernard Bakker, head of the Technical Department explains: “The torque of the robot’s motors are continually monitored and any increase above expected torque within a programme is sensed and the robot stops instantly.”


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“There are many positives about the systems we have installed but what we like about the robots is that we seem to keep learning about different functions and ways they can be used effectively. We were especially impressed by the speed of one robot, where other suppliers offered us two robots for the same amount of work. When we were looking to invest in robots we were shown a demonstration of the FANUC robot at Dero’s premises. We were impressed by the speed and this helped to convince us that robots were the way ahead.” Christiaan Hallers, Project Manager, K.H. de Jong

Other features include being able to sense that all cheeses have been picked up with the vacuum grippers – if a cheese is left on the tray the robot is aware and returns the tray to the rack slowly to avoid dropping the cheese. Also as the cheeses are not a uniform ‘ball shape’ the robot is able to perform a ‘human like’ wrist roll motion over the cheese to ensure a good contact is made with the vacuum gripper. This roll motion also ensures cheeses do not stick to the tray. ” Sensors on the conveyor provide a count to the robot to indicate the next available position to deposit the seven cheeses – this ensures the conveyor is kept full. The conveyor transfers the cheese to a paraffin wax coating machine that produces the familiar Edam coloured protective coat. After coating and in most cases wrapping in cellophane and labelling, the conveyor delivers the cheese to a FANUC Robotics M-710iC robot which has a specially engineered gripper with six individual pneumatically operated ‘finger type’ grippers. Picking up three cheeses and rotating 180º to pick up another three the robot then places the six cheeses into a freshly erected box. Rotating through 180º ensures that the labels are always positioned towards the outside of the box to avoid damage from contacting the top edge of the cartons internal separator. Full boxes are released from the loading area and proceed to a FANUC Robotics M-410i palletising robot at the end of the line. Christiaan, continues, “Using the M-710iC robot for the process of placing the cheeses in the box has helped greatly – in particular the robot is able to change its own gripper which weighs 40Kgs. This was previously a two person job and took a lot more time.”


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25

FANUC M-410iB palletising

The line has made a significant impact on productivity at KH de Jong and labour cost has been driven down. Christiaan explains, “We operate two shifts and labour cost savings equate to 500 hours per week, in addition productivity has increased by at least 10%. The system has provided us with a maximum capacity of of 3,600 cheeses per hour per line. Handling the trays was a potential injury risk area as the metal trays can get damaged and arrive with sharp edges. Also quality has improved and, as the cheese is no longer handled manually, hygiene is maintained.“ The implementation of robots into the KH de Jong facility has been well received by the workforce. Management ensured that employees were involved and kept aware of the importance of remaining competitive by improving quality, productivity and reducing costs. Overall the robots are well liked by employees who no longer have to carry out what they thought was an annoying packaging task. Christiaan concludes, “There are many positives about the systems we have installed but what we like about the robots is that we seem to keep learning about different functions and ways they can be used effectively. We were especially impressed by the speed of one robot, where other suppliers offered us two robots for the same amount of work. When we were looking to invest in robots we were shown a demonstration of the FANUC robot at Dero’s premises. We were impressed by the speed and this helped to convince us that robots were the way ahead.”

AT A G L A N C E • KH de Jong packages over 350 tons of Edam cheese per week • FANUC Robotics robots used on packaging lines to handle cheese • Handling requires intelligence to overcome inconsistency of product shape and also occasional sticking tray problems • FANUC Robotics intelligent controller used to control system and ensure inconsistencies are detected and overcome • Quality of product has improved and hygiene is maintained as cheese is no longer handled manually • Employee involvement at all stages of robot implementation has maintained their interest and support • Labour cost savings equate to 500 hours per week and productivity has increased by 10% • Robots have provided a maximum capacity of 3,600 cheeses per hour per line


THE FANUC FOODLINE M-430iA · LR Mate 200iC · M-10iA · M-20iA · M-420iA M-710iC · M-410iB · R-2000iB · M-900iA · Controller

FOOD

LINE


02


03

FANUC Robotics offers the most flexible solution to any picking, packing or palletising problem straight out of the box; and because all FANUC Robotics products are developed around proven technology they are renowned for their high levels of reliability. With a range capable of handling from 2kgs to 1200kgs, and best in class picking rates, there’s a FANUC robot for every application. It’s the widest range of robots available on the market together with application specific software to make programming straight-forward. There’s over 200,000 FANUC robots installed around the world and keeping them supported is a priority – FANUC Robotics worldwide network is never far away from any user to provide advice and support. This section is designed to provide an insight into the features and benefits of specific products suitable for picking, packing and palletising in the food sector. Of course we’re limited here as to the amount of information that can be provided so if you need further information on any product or service contact your FANUC Robotics country office – see addresses below or visit www. fanucrobotics.lu FANUC Robotics Benelux

FANUC Robotics Deutschland GmbH

FANUC Robotics Ibérica S. L.

FANUC Robotics (UK) Ltd.

FANUC Robotics Polska Sp. z o.o.

000 FANUC Robotics Russia

Tel.: +32-15-207-157

Tel.: +49-7158-9873-0

Tel.: +34-93-664-1335

Tel.: +44-2476-63-96-69

Tel.: +48-71-77-66-160

Tel.: +7-49-56-65-00-58

www.fanucrobotics.be

www.fanucrobotics.de

www.fanucrobotics.es

www.fanucrobotics.co.uk

www.fanucrobotics.pl

www.fanucrobotics.ru

FANUC Robotics Czech s.r.o.

FANUC Robotics France

FANUC Robotics Italia S. r. l.

FANUC Robotics Schweiz

FANUC Robotics Magyarország Kft.

Tel.: +420-234-072-900

Tel.: +33-1-69-89-7000

Tel.: +39-02-9345-601

Tel.: +41-56-641-03-70

Tel.: +36-6-23-507-400

www.fanucrobotics.cz

www.fanucrobotics.fr

www.fanucrobotics.it

www.fanucrobotics.eu

www.fanucrobotics.eu


04

PICKING

THE M - 43 0i A /2 F IS A 5-AXE S HANDL ING ROBOT WITH 2KG PAYLOAD, SP ECIALLY DEVELOPED FOR FO OD APPLI CATIONS. IT OFFERS H IGH RATES OF CON T IN UOUS H A N DL ING OF OBJ ECTS, A CLEAN, WASH ABLE MECHA NICAL UNIT, AND A CH EMICAL-RESISTANT SUR FACE.

900

mm

Reach

m

70

0

0m

90

m

iA/ 2

mm

F

m

430

43

0i A/

430 iA/2

2P

PH

H

2F

/ iA 30

m

900 m

4

/4FH 430iA

2K

g

4 Kg

g

2

2

Kg 2K

900

Weight

Kg


M-430iA SERIES

05

FEATURES AND BENEFITS VERY HIGH SPEED PICKER Dual drive torque tandem control is applied for J1, J2 and J3. The M-430iA/2F can handle • Up to 120 cycles / minute in continuous motion • Up to 200 cycles / minute in dual arm configuration ROBOT ARM DESIGNED FOR FOOD INDUSTRY CLEANING REQUIREMENTS • Special coating and sealing which protect against hot water, acid and alkaline cleaners • Perfectly smooth surface of the whole unit for easy cleaning, thus avoiding the contamination by germs • IP67 FLOOR AND CEILING MOUNT, LARGE WORK ENVELOPE • The M-430iA/2F offers a very large work envelope compared to other types of robots, thus providing high flexibility for cell design. • The M-430iA/2F can be floor or ceiling mounted. FOOD GRADE GREASE M-430iA/2F • Special food grease to avoid any risk of damaging food with grease or oil

NO GREASE IN WRIST AXIS UNIT • No risk of contamination of grease on food, even in case of heavy collision of wrist axis HOLLOW ARM STRUCTURE • No outer cables • Same life for cables and other internal components • No risk of damaging cables • Less spare parts necessary • Cost saving on maintenance MOTORS DIRECTLY COUPLED TO THE REDUCER • Simplified mechanical unit • Reduced breakdown risk • Compact and reliable solution • High accuracy and minimum backlash HOLLOW JOINT CONSTRUCTION FOR REDUCERS • Reduced wear of cable routing as most reducers have hollow construction


06

PICKING

THE LR MATE ROBOT SERIES OFFERS THE SMALLEST MODELS WITHIN THE FANUC ROBOT RAN GE, FROM 2 TO 5KG PAYLOAD. THEY ARE IDEAL FOR FA S T AND PRE C I S E APPLI CAT I O N S IN ALL ENVIRO N M E N T S. THEY RUN ON THE R-J3iB MATE OR R-30iA MATE COMPACT CONT ROL L ERS, WH ICH REQUIRE MINIMUM SPACE.

m 704

892

mm

Reach

L/5 LC

m

4m

iC 200

m 20

711

0i C/

200i C/5F

m

5C

0 20

5H

mm

m

4

70

200 iC/5

70

/ iC

m

704 m

/5WP 200iC

5 Kg

5 Kg

5K

g

g

5K

g

5K

g

5K

Weight


LR MATE SERIES

07

FEATURES AND BENEFITS VERY HIGH THROUGHPUT • Calculated TCP speed of more than 4 meters / sec • Cycle time of 120 cycles / mn This makes it the fastest robot in its class COMPLETELY IP67 WITH “SEVERE DUST LIQUID PROTECTION (SDLP)” OPTION • Dustproof • Can be immersed in water

COMPACT ROBOT DESIGN • Easy to integrate into a work cell • Less interference area • Takes up less floor space • Reduced investment


08

PICKING

THE M-10iA/M-20iA ROBOT SERIES OFFERS A HIGH FLEXIBILITY FOR APPLICATIONS FROM 6 TO 10KG PAYLOAD. THEY OFFER A HIGH SPEED WHICH MAKES THEM IDEAL FOR PICK & PLACE AND MACHINE TENDING OPERATIONS.

m

m

18

20

11

14

m

m

Reach

iA

m

iA

M-1

0iA /6

10

0L

A/1 20i

M-

L

6K

g

Kg

10

20

Kg

Kg

Weight

m

8m

200

-2 0

10 M-

2m

M

163


M-10iA AND M-20iA SERIES

FEATURES AND BENEFITS FLOOR, CEILING (ANGLE AND WALL) MOUNTING METHOD • Ceiling and angle mounted robots provide : · Easier access to the machine being serviced · Easier access to the parts load / unload area • Allows maximised use of the robot work envelope BEST INERTIA IN ITS CLASS • High wrist inertia provides the ability to handle tools at high speed

WRIST AND J4 ARM IP67 • Waterproof wrist can be immersed into water • Improved reliability in dusty environments

09


10

PACKING

THE M - 42 0iA ROBOTS ARE DESI GNED SPE CIFICALLY FOR HIGH S P E E D HA NDL I NG AND PACK AGING APPL ICATIONS. ALL M -420 iA ARE FLOOR MOUN T ED.

Reach

m

m 55 18

55

m

55

0iA 42

18

mm

18

42

0iA (H

S)

1iA

42

30

Kg

40 Kg

50

Kg

Weight

m


M-420iA SECONDARY FOOD

11

FEATURES AND BENEFITS SPECIAL PURPOSE MECHANICAL DESIGN Designed specifically for high speed handling and packaging applications • Minimum floor space needed • Very high speed operation with heavy payloads • Large work envelope for pick & place applications

ROBOT ARM DESIGNED FOR FOOD INDUSTRY CLEANING REQUIREMENTS • Special coating and sealing which protect against hot water, acid and alkaline cleaners • Perfectly smooth surface of the whole unit for easy cleaning, thus avoiding the contamination by germs • IP 67 FOOD GRADE GREASE • Special food grease to avoid any risk of contaminating food with grease or oil


12

PACKING

THE INNOVATIV V E M-710iC SERIES OF ROBOTS IS DESIGNED TO HANDLE MEDIUM PAYLOADS OADS (20 TO 70KG) WITH A SLIM WRIST WRIST, RIGID ARM A AND SMALL FOOTPRINT, SUITABLE FOR A WIDE RANGE OF APPLICATION.

20

50

mm

Reach

13

mm

10

31 L

20 S

50

50

70

mm 20

Kg 50

50

Kg

Kg

70

50

60

20

Weight

Kg

mm


M-710iC SERIES

13

FEATURES AND BENEFITS FLOOR AND CEILING MOUNTING (ANGLE AND WALL) WITH RESTRICTIONS • Easier access to the machines being serviced • Maximised use of the robot work envelope

HIGHEST AXES SPEED Makes it the fastest robot in its class Allows handling larger or heavier work pieces Allows servicing larger and higher pallets

COMPACT WRIST : NO MOTORS AND IP 67 • No electrical elements at wrist : all motors for wrist motion are mounted on the robot’s shoulder at J3. · Reduced risk of damaging the wrist motors because of high heat or harsh environment · Compact design to access narrow spaces · High loads and high duty cycles possible thanks to good air cooling of the wrist motors • Wrist unit sealed against dust and water according to IP 67

M-710iC variation for 2 nd Food Handling • M-710iC 2nd Food is designed for secondary handling applications e.g. of cheese, meat, fish and other foods. Its body is designed for cleaning and its apoxy paint is durable against regular sanitation. The wrist axes are greased by food grade grease to provide extra safety against any food contamination. • With its far reach and high payload the M-710iC robot is ideal for food packaging and palletizing.


14

PALLETISING

THE M-410iB B SERIES OFFERS 4-AXES 4 AXES ROBOTS DEDICATED TO PALLETISING APPLICATIONS WITH PAYLOADS RANGING FROM 160 TO 700KG. FANUC WAS ONE OF THE FIRST ROBOT SUPPLIERS TO DEVELOP A ROBOT SERIES SPECIFICALLY FOR PALLETISING NEEDS AND CAN NOW RELY ON YEARS OF EXPERIENCE IN AUTOMATING THE END OF PRODUCTION LINE.

43

31

31

43

m

m

mm

mm

m

0iB /

0

41

-4

30

/ 0iB M-

0m

313

10 iB /7 00

41

M-

43

M

31

16

0

50

/4 0iB

41 M-

16

0K

g

g 0K

g

0K

30

45

g

0K

70

Weight


M-410iB SERIES

15

FEATURES AND BENEFITS INTEGRATED BASE AND CONTROLLER Pedestal and controller are provided with the robot as standard • Reduced floor space requirements in factory • Easier robot transportation • Reduced installation time enabling quicker production start up OPTIMISED DESIGN FOR PALLETISING The dedicated design increases throughput for palletising and load / unload applications • Multiple palletising positions • Access to the work piece from the upper side, no interference between robot arm and palletised work pieces • 360° rotation on J1 axis for a large work envelope

HIGH ALLOWABLE WRIST MOMENT AND INERTIA • Ability to handle large gripper and heavy payload at high speed, thus providing higher throuhput • Flexibility on gripper design and material used


16

PALLETISING

THE R-2000iB SERIES IS FANUC ROBOTICS LATEST GENERATION OF THE MOST SUCCESSFUL FANUC ROBOT IN THE WORLD. WORLD ITS LARGE RANGE OF PAYLOAD FROM 100 TO 210KG AND ITS HIGH PERFORMANCE CAPABILITIES MAKES IT THE PERFECT SOLUTION FOR MULTIPLE APPLICATIONS. ALL R-2000iB ARE FLOOR-MOUNTED.

125

2655 mm

m 26 55 m

R

0F

200

F

0P

10

L

m

100 Kg 125

g

Kg

0K

Kg

10

16

5

Kg 200

21 0K

g

g 5K

16

g 175 K

Weight

m

2655 m

CF 170 150 U

100 H

m

0m

152

150 Kg

170

m

00

35 21

5R

5

m

175 L

16

16

5m

309

m

m

m

m

300

5m

m 2852

m 95

30

26

55

m

Reach

Kg


R-2000iB SERIES

17

FEATURES AND BENEFITS COMPACT WRIST : NO MOTORS AND IP 67 • No electrical elements at wrist : all motors for wrist motion are mounted on the robot shoulder at J3. · Reduced risk of damaging the wrist motors through of high heat or harsh environment · Compact design to access narrow spaces · High loads and high duty cycles possible thanks to good air cooling of the wrist motors • Wrist unit sealed against dust and water according to IP 67

HIGH ALLOWABLE WRIST MOMENT AND INERTIA • Ability to handle large gripper and heavy payload at high speed, thus providing higher throughput • Flexibility on gripper design and material used OPTION : SEVERE DUST LIQUID PROTECTION • Main body protected from dust and water jets – IP 56 • Wrist part dustproof and can be immersed in water – IP 67 • Drivetrain (motors, reducers, gear drive shaft) – IP 66 • Anti-corrosive bolts


18

PALLETISING

THE M -9 0 0i A 6-AXES ROBOT SE R IES HAS ONE OF THE HI GHEST PAYLOADS AVAILABLE IN THE MARKET TODAY, DE SIGNED TO HANDLE VERY HEAVY OR MULTIPLE PARTS (260 TO 700KG PAYLOAD).

36

25

m

mm

m

50

26 35

mm

m

0m

L

00

0

40 0

31

26

283 600

0L

26

0K

35 g

0K

40 0

0

/70

600

Kg

g

Kg

Weight


M-900iA SERIES

19

FEATURES AND BENEFITS FLOOR AND CEILING MOUNTING M-900iA/260L AND M-900iA/350 (ANGLE AND WALL ALSO POSSIBLE) • Easier access to the machine being serviced • Maximised use of the robot work envelope Note : the M-900iA/600 is floor mounted

SEVERE DUST LIQUID PROTECTION (SDLP) OPTION Main body protection from dust and water jets – IP56 Wrist part dustproof and can be immersed in water – IP67 Drivetrain (motors, reducers, gear, drive shaft) – IP 66 Anti-corrosive bolts HIGH ALLOWABLE WRIST MOMENT AND INERTIA Ability to handle large gripper and heavy payload at highspeed Improved carrying capability providing higher throughputs


20 FANUC ROBOTICS SYSTEM R-30iA CONTROLLER USES ADVANCED TECHNOLOGY PACKAGED IN A PROVEN, RELIABLE AND EFFICIENT DESIGN. PROCESS CAPABILITY AND OPEN ARCHITECTURE FEATURES PROVIDE INTELLIGENCE TO IMPROVE APPLICATION AND MOTION PERFORMANCE WHILE SIMPLIFYING SYSTEM INTEGRATION INTEGRATION. THE R-30 R-30ii A CONTROLLER INCORPORATES FANUC ROBOTICS UNIQUE “PLUG-IN OPTIONS” CONCEPT, WHICH GIVES FLEXIBILITY FOR APPLICATION SPECIFIC CONFIGURATIONS WHILE MAINTAINING A COMMONALITY FOR ALL USERS OF THE SYSTEM.


R-30iA CONTROLLER

21

POWERFUL PROGRAMMING FUNCTIONS The controller runs with FANUC operating system, which brings strong advantages : • Virus-free (not PC based) • High data security in case of power loss • Quick start-up of basic software • Easy to use The controller offers various programming possibilities : • TPE (Teach pendant editor) which is the standard way of programming • Advanced offline programming options such as ROBOGUIDE • Integrated PMC (optional) • Karel (optional) TPE is a block style interpreter language : allows fast and cost-efficient programming • Possibility to record up to 11 000 positions with basic memory configuration • One key stroke on the teach pendant records one complete operation of the robot • Standard operations (e.g motion, arc start, arcend, logic,…) can be selected and adapted to the applications very easily • TPE motion includes : · Joint, linear and circular motions · Remote TCP, coordinated motion and other functions in option

FEATURES AND BENEFITS FAST START-UP R-30iA controller needs less than 1 minute to start (and even less with the basic software only). In case of power failure: • Robot program restarts much quicker than with any PC-based program (non-Windows operating system). • The resume hotstart function allows to restart safely and continue production after power failure: no need to re-do the whole movement. • Unique resume tolerance check: in case of any program interruption, the robot automatically memorises its position before failure. When the program continues, it checks wether the robot has been moved outside of a preset tolerance. This avoids unexpected movements and collisions. • Increased up-time (robot availability) iPENDANT AS STANDARD The FANUC i-Pendant is an intelligent teach pendant and is available as standard (except for PaintTool). Touch screen is available as option. • Access via Ethernet to web sites • Pendant view status of peripheral equipment and other robots‘ html web server pages (when available) • Coloured, multi-windows display • Customizable screen Easier work with the robot, enhanced productivity.

EXTENDED AXES CONTROL R-30iA The controller can manage up to 40 axes 1) that are using FANUC motors (divided in upt to 8 groups; one group can control up to 9 axes), such as: • 4 robot arms + • 4 auxiliary axes groups (arc welding positioners, robot rails, servo hands, grippers... ) There are three types of motion control available: • Extended auxiliary axes: for robot rails and simple tools (grippers) • Nobot: for servo driven tools and other intelligent peripherals • Positioner: for arc welding positioners, with coordinated motion between robot and positioner. Following options are available as extensions of this feature: • Aux Axis servo off: for safety design of manual in/out-feed stations • Torque limit: in order to control the gripping force of servo grippers • Servo hand change function: which allows the changing and disconnecting of servo hands and tools • Continuous turn: for tools and positioners needing endless rotation • Multi-motion for multiple groups • Multi-robot control (dual / multiple arm) for more than one robot)


22 i RVISION IS ENTIRELY INTEGRATED WITHIN THE FANUC R R-30 30ii A CONTRO CONTROLLER OLLER.


iRVISION

23

FEATURES AND BENEFITS iRVISION 2D

3DL VISION

FOUR PROCESSES POSSIBLE • Normal 2D Vision process • Depalletising 2½D Vision process • 2D Multiview Vision process • Visual Line Tracking 2D Vision process

3DL Vision is used for reliable part location and orientation, regardless of variations in part size and occlusions. It allows Bin Picking and Panel Picking. • Recognition of parts position ( X,Y,Z ) and orientation ( W,P,R ) • 100% FANUC Product ( Hard- and Software )

EASE OF USE • Fast and easy set-up • Easy application building • Integrated instruction set • Fully integrated in Robot Controller (no PC/WINDOWS needed) AUTO EXPOSURE MODE Light fluctuation compensation CALIPER FUNCTION iRVision can check distance between two lines HISTOGRAM TOOL The Histogram Tool visualises possible grey scales around the piece. The goal is to recognise if there is enough free space around the piece for the gripper. This avoids parts to be broken and reduces costs. DEPALLETISING 2½D VISION PROCESS This Vision Process Type supports a calculation of a Z-height and some special depalletising functions. The new functions are also supported. 2D MULTIVIEW VISION PROCESS This Vision process type supports the very accurate detection of huge parts. The vision information of two cameras is used to find the correct position. The setup and usage is very easy and fast. The new functions are also supported. VISUAL LINE TRACKING This vision process supports the Visual Line Tracking Function with special support for the fast and easy setup of Line Tracking schedule and camera calibration. ENHANCED PROCESS SOLUTION Visual Line Tracking provides robotic process solutions for: • Sorting non-fixtured parts on moving conveyors • Picking up non-fixtured parts on moving conveyors • Placing parts onto fixtures located on moving conveyors

FANUC Robotics Food magazine 2010  

Special issue of FOOD Sector Robotics Review. FANUC Robotics has been supplying robots to manufacturing industry since 1982 and many of thes...