ABB automates machine tending for machine tools

With the new FlexLoader™ M family, ABB brings the benefits of modularity to machine loading, according to the press release. In summary, three advantages are mentioned:

• Intelligent cells for robot-assisted machine tool loading - easily expandable thanks to standardized modules
• High flexibility to cope with different requirements - fast teach-in of new workpieces within a few minutes
• Simple, camera-based programming possible even without specialist knowledge - to increase machine utilization

Since ABB is in the higher-priced segment, perhaps less interesting for SMEs, but on the other hand, the blog is also read by employees of larger companies and then this news again shows that something is happening in the market. ABB does not rely on cobots here, but on classic industrial robots. To the press release(website):

ABB has expanded its product portfolio with a new family of modular machine charging cells for the metalworking industry. They enable companies to increase flexibility and machine utilization while minimizing productivity losses due to unforeseen production interruptions. With six different variants, the FlexLoader™ M family offers a wide range of options for loading and unloading machines - depending on the size, shape and quantity of the workpieces to be processed. The new models are therefore ideal for use in foundries and die casting operations, for example, which manufacture many product types in different quantities.

"As their customers demand ever greater product variety and shorter delivery times, metal fabricators need a manufacturing process that is fast and agile. At the same time, it needs to be flexible enough to allow them to produce with high variance and small volumes down to batch size 1," emphasizes Andrea Cassoni, head of the General Industry business line at ABB Robotics. "FlexLoader M pays attention to exactly that. With it, we provide a central platform for machine tool loading. It provides the flexibility needed to handle a wide variety of production requirements while increasing productivity. This is because the time, costs and also interruptions normally associated with production changeovers are eliminated."

At launch, ABB offers models with drawers (trays) and conveyor (conveyor) - other variants will follow in the coming months. FlexLoader M Conveyor features a simple but powerful vision system that enables feeding of workpieces with complex shapes. This allows numerous workpieces to be processed flexibly with just a single cell. FlexLoader M Tray is a drawer solution that allows easy loading of the machine. Thanks to a minimal footprint, the cell can be set up almost anywhere, making it ideal for handling different workpieces with variable shapes such as cubes, cylinders, plates and tubes.

With standardized, interchangeable modules, FlexLoader M provides a flexible and scalable solution for a wide range of machine tools, including lathes, milling machines and CNC machining centers. A key benefit is the ability to use the same base machine and swap out feeder modules as needed. This modular approach enables uncomplicated upgrading and expansion. On average, only one to two days are required for installation and commissioning.

With FlexLoader M, ABB is meeting the ever-increasing demand for simple automation solutions that can process more workpieces in less time. The robot cells are user-friendly and quick to program - even without special robotics know-how. With the help of an intelligent wizard, operators can teach in new workpieces in less than five minutes without having to have any expertise in image processing. In addition, switching between already programmed parts is possible in less than a minute. Thanks to the simplicity of the programming software, operators can be fully trained in less than half a day, further reducing the time required to commission the cell.

What's more, with FlexLoader M, labor costs for machine loading can be reduced by up to 90 percent, as one employee can operate up to ten cells simultaneously. The automated solution enables machine utilization of over 97 percent, compared to 40 to 60 percent for manually operated machines.

All variants can be equipped with a vision system that identifies the position of the workpiece and transmits appropriate commands to the robot, machine tools and other cell components such as air cleaning stations, part marking, deburring and measuring systems. The vision system supports both a 2D camera and a 3D sensor, depending on the application.

FlexLoader M also has data-based optimization features, including remote monitoring, that allow the operator to troubleshoot and make improvements "remotely". Furthermore, the vision software offers additional functions such as condition monitoring, fleet management, and performance and job management.

With FlexLoader M, ABB replaces its current FlexLoader cells, which have proven themselves for many years thanks to their reliable production management. All FlexLoader cells enable higher utilization of machine tools as well as unmanned production. They have proven many times that they provide a faster return on investment and give users a sustainable competitive advantage.

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The author of this blog is significantly involved in the AI/ robotics project Boost-Bot. He advises robotics companies and investors on market (entry)/ business development and funding/subsidies. The standard book on cobots is also written by Guido Bruch (however, the book is already 2 years old and therefore not quite up to date). More about him can be found here.