ABB has launched a new family of modular machine tending application cells for the metals industry, aimed at maximising flexibility and machine utilisation while minimising lost productivity caused by unforeseen production stoppages.
Featuring six different versions, the FlexLoader M family is designed to offer a variety of ways of loading and unloading machines based on the size, shapes and amount of the workpieces being handled. ABB said this makes the family of robots ideal for applications such as foundries and die casting operations producing multiple types of products in varying quantities.
“As customers demand greater variety and shorter delivery times, metals producers need to have a manufacturing process that can respond quickly and offer the flexibility to achieve high mix, low volume and batch size one production,” says Andrea Cassoni, managing director for business line General Industry for ABB Robotics.
“FlexLoader M is accelerating this move by providing a single unified machine tool tending platform offering the flexibility needed for handling a wide variety of production demands, whilst also improving productivity by eliminating the time, cost and disruption traditionally associated with production changes.”
The launch starts with Tray and Conveyor variants, with further variants due for release over the coming months. The FlexLoader M Conveyor uses a vision system to enable loading of workpieces with complex shapes, and handle a variety of workpieces within a single cell.
The FlexLoader M Tray is a drawer solution which aims to offer easy machine tending. With a minimal footprint that allows it to be located almost anywhere, it is ideal for handling a variety of workpieces with variable shapes such as cubes, cylinders, plates and pipes, according to ABB.
Featuring standardised interchangeable modules, the FlexLoader M is built to offers a flexible and expandable solution for a wide variety of machine tending applications including lathes, mills, CNC and machining centres. ABB added a key benefit is the ability to use the same base machine, exchanging in and out feed modules as requirements change.
ABB predicts the FlexLoader M can reduce labour costs for machine tending processes by up to 90%, with one operator able to handle up to 10 cells simultaneously. The automated system delivers machine utilisation of over 97%, compared to 40-60% in manually operated machines.
All the variants can be equipped with a vision system that identifies the workpiece’s position and gives commands to the robot, machine tools and other cell equipment such as air cleaning stations, part marking, deburring and measurement systems. The vision system can use either a 2D camera or 3D sensor depending on the application.
