The new Flex Finishing of ABB system revolutionizes the field of Robotics

For a long time it has been difficult for robotic applications engineers to achieve a fast moving and maintaining at the same time the stability of the contact with

the piece. For several years, ABB has highlighted in this field develop robots that could carry out delicate Assembly tasks in the automotive industry. This progress has been achieved by the use of sensors which measure force

contact and loops of feedback that they control the strength and her suit to the movement of the robot arm. With these robots of force controlled working with robots S4Cplus driver, Assembly of propellant groups time could

reduce by up to 75 percent. Recently, has managed to go a step further in the use of robots of force controlled in a more complex class of applications: grinding, deburring and polished of manufactured units, for example, in a casting workshop. In contrast to the Assembly of parts, the control of the forces of the process in these applications is much more demanding, and until now it wasn't possible to get it. There are several reasons for this increased complexity: the wear of tools, variable dimensions of parts and the lack of a total accuracy and repeatable of the media, with the risk of large deviations of position and irregular results. Traditionally, the finishing process has specified labour-intensive, and the quality of the finished product has not agreed with the grinding, deburring and polished manual. So far, the position of the robots used for this task was controlled with tools and adaptable housings, with paths and defined speed, sometimes aided by an extra servo motor to adjust the variations in the dimensions. In this mode of operation, if the robot can not reach the fixed path because the piece is not placed correctly, continue to cut through it. As a result, the robot stops, the tool breaks or the piece is damaged. To limit the damage, classic castings cleaning robots operate at a slower pace with limited productivity. Due to the need for control of position, these robots must be programmed to accommodate a high precision in the path, an effort which requires long time engineer. All these drawbacks were slowing the expansion of the applications of the robots in this industry.

The new and exclusive Robotics application released by ABB in 2007 combines five innovative elements: employment last controller of robots from ABB, the IRC5, with its high speed sensors interface, programming to environment

allows the robot to find itself only the optimal path, a loop of feedback that controls the pressure of the tool, a loop of feedback that adjusts the speed of the tool and a range of easy to use product and preadaptado.

The IRC5 is built on the most advanced operating system for the control of robots and peripheral equipment industry. With Rapid language and the operating system for robotic Motion Technology and Communication (movements and communications technology) of ABB, it is existing more powerful controller operating system now. IRC5 has two Ethernet channels, one for the LAN and another for local connection, as well as two-channel series for communication point to point with sensors. The bandwidth provided by the controller IRC5 is critical for global benefits and the reaction time of the robot in order to correct and adjust its position. To achieve adequate sampling rate to adjust the dynamic positioning of the robot, the sensor must be closely integrated with the electronics of the driver if this innovative application to produce good results. The IRC5, equipped with Motion Technology MultiMove of ABB, is a benchmark that allows simultaneous control of up to four robots (36 axes). The robots can share common objects, thus allowing coordinated complex configurations. MultiMove also facilitates the dynamic exchange between independent and coordinated movements. This unique feature makes it possible to deal with the complex of rectifying, deburring and polishing tasks. The programming environment that supports the user of this innovative application is the first to offer this new dimension of programming. It allows a simple and effective programming to use the own force sensor to define the trajectory of the movement of the robot. The programming is managed from the FlexPendant and a unique module of the application to create the program for Force Control Machining (machining with control of force). The concept provides the operator the possibility to move the robot hand and teach you the approximate trajectory. Later, the robot automatically uses approximate information to follow the piece; at the time, it will automatically register the exact path and create a robot program. FC Pressure feedback loop allows the robot to rectify, pulimente or pula objects melted to maintain a constant pressure between the tool and work surface. FC Pressure software is intended for processes that require a high quality finished surface. It allows the robot to 'feel' effectively their environment and follow the surface of the casting, changing his position to apply pressure on the surface, even if its exact position is unknown. While there is a continuous contact, the burrs and other leftovers are removed to the same depth.

The result is a better surface finish, the ability to accept variations in the foundry, a minimal risk of damage to the surface of cast iron and a predictable wear of the tool. Since that pressure is achieved by moving the trajectory of the robot, this function is given especially to the operations of polishing, grinding and cleaning when the surface must be smooth and regular. The second characteristic of the FC SpeedChange software allows the robot machining surfaces of cast iron at constant speed and go more slowly when he finds too many burrs. In processes where the accuracy of the trajectory is important and where the result of the finish must satisfy dimensions specific, FC SpeedChange is the right choice. With FC SpeedChange, controls the position of the robot and it follows a programmed path that retains a constant rate of removal of material. Working at the maximum speed of process and slows down the robot automatically when the forces of machining are excessive, to minimize dimensional variations due to the deformation of the robot arm, and to avoid the consequent damage in the piece or the tool because of the effort and the heat. As in the case of FC Pressure, this translates into a duration less than cycles, the ability to accept variations in the castings, in a minimal risk of damage in the pieces and a predictable wear of the tool.

The final product includes an advanced processing of the signal of the sensor, mathematical functions, logical solution and a graphical user interface to a quick, easy and accurate programming which is used sensor so that the operator guides the robot hand with a view to a direct and intuitive programming. The product ' Plug and use ' contains all the necessary components, with the sensor, electronics and wiring mounted and tested on the robot, and leaves only the Integrator or customer adaptation process.

This complex and multidisciplinary task has forced to combine the work of researchers from many universities and ABB, ABB and customer engineers. ABB and the Technical University of Lund began together the first steps to define and implement the basic sensor and control [2.3] functions. From this perspective, it became necessary to improve the knowledge of the application and find the optimal user interface [4]. How to make the work a success was clear, and was to meet the global resources of ABB with actual cases to bring it to the test provided by the industrial partners. John Kuhn, Rimrock Corporation, who carried out tests in real time, said: "Force Control can influence our activity more than any other product released by ABB to date". Rimrock Corporation is a leading provider of automation products and services integration in North America and a valued partner of ABB for a long time.

When presented to the public for the first time RobotWare Machining FC at the Gifa, the largest exhibition of foundry in the world, to be held in Düsseldorf, the commotion among the clients was unstoppable. Customers clearly proved the better product quality and considerable savings in time of engineering, which can now reach 80 per cent. In addition, the duration of the cycle of the robot is reduced by around 20 per cent with the enhanced control, and life of machining tools can extend also by 20 percent. After the successful launch of the Force Control technology for Assembly and machining applications, ABB is involved in new areas. One of them is the aerospace industry, where works by drilling with accurate, reliable and efficient robots are required to achieve a flexible production.

Now, with RobotWare Machining FC, the finishing of products in the smelting operations are much more simple and allow to get strained parts finished better, more quickly and at a better price.