2009 International Robots, Vision & Motion Control Show

 

By Bill Lydon - Contributing Editor

 

June 9-11, 2009 Rosemont, IL

 

The combination of more agile robots, vision systems, and the integration of robot and vision recognition software is creating some very “intelligent” robots.  These capabilities are expanding the type and number of applications possible. After talking with various vendors, I believe the economic downturn, particularly in the automotive industry, forced them to think “out of the box, about other applications. A positive reaction to crisis can increase our creativity to reach beyond to new applications, ideas, and combinations. A crisis can have some lasting benefits for those that use it as an opportunity.

 

The show was busier than I and many exhibitors had expected. Attendance at the show was about 4,000 with 140 exhibitors. One exhibitor had not intended to do any shows this year and decided to exhibit at the last minute based on sales recently improving. The show is produced and sponsored by the Robotic Industries Association, Automated Imaging Association (AIA), and Motion Control Association.  The conference featured tutorials and application sessions on robotics, machine vision, and motion control.

 

ABB featured its “Robotics on the Move” expandable 53 foot trailer. This is the first time the trailer has been used as the main focus of a major international trade show. The “Robotics on the Move – Partnership in Productivity Tour” travels around North America during the year, visiting manufacturing plants, engineering companies, technical colleges, and regional manufacturing expositions. The goal of the exhibit is to educate manufacturers on the latest robotic trends and technologies, and to identify ways manufacturers can utilize robotics to their complete potential to increase productivity and competitiveness in the marketplace.

 

    

The trailer included live demonstrations of TrueView - ABB’s vision guided robotics solution, and an IRB 1600 ID robot simulating an arc welding application. In addition, the trailer offered video presentations on SafeMove Remote Monitoring on a robotic installation, Robot Studio software applications, and much more.

 

 

 

TrueView is the brand name for ABB's Vision Guided Robotics (VGR) System that combines ABB robots, off-the-shelf hardware and an eVisionFactory (eVF) software platform into a fully integrated package.

 

With TrueView, robots are able to “see” and “comprehend” information about their environment, such as variations in part position, type, style and quality, in real-time using a robot-mounted single camera and variable lighting package.  TrueView is capable of full 6 degree-of-freedom 3D vision guidance. The robot is programmed to position the camera and adjust the lighting to an optimal image capture location. The eVF software processes the image and sends the appropriate path adjustment to the robot via Ethernet. This approach to vision guidance allows for automatic calibration and part training - which in turn shorten solution development and integration lead times. TrueView VGR systems see and react to changes within the industrial work environment, enabling ABB robots to precisely locate the grip points of a disoriented object within a 3D space. www.abb.com/robotics

 

FANUC Robotics America Inc. introduced two new robots — a super heavy duty robot and the new M-1iA intelligent assembly robot.

 

The FANUC demonstration of the new M-2000iA/1200 super heavy-duty robot was impressive. The new M-2000iA/1200 equipped with iRVision® 2D error proofing and Dual Check Safety (DCS) Speed and Position Check Software demonstrated its high capacity payload and wrist by loading and unloading a machine tool bed weighing 1350 kg into a machine tool. The robot transferred the machine tool bed in front of a 2D camera, and iRVision error proofing inspected the part for proper machining of T-Slot guideways that hold tools.  “The M-2000iA/1200 has the highest payload and the strongest wrist compared to all other electric six-axis robots available today,” said Ian Orr, product manager, FANUC Robotics. It can support a 1350 kg payload with a 0.6 m offset from the faceplate and full articulated motion at the wrist. One M-2000iA/1200 robot can handle a super heavy part, which previously required dual robots, conveyors, lifts, and other fixed automation. 

 

FANUC demonstrated two M-1iA robots equipped with iRVision 2D that assembled and disassembled a 10-key keyboard at high speeds.  The new M-1iA intelligent assembly robot is a lightweight and compact six-axis; parallel-link robot designed for small part handling, high-speed picking, and assembly applications. The parallel-link structure provides higher speeds and accuracy compared to traditional assembly robots. The robot can be installed in a variety of orientations, and has a three-axis wrist, making it extremely flexible. The M-1iA also offers a four-axis model for simple assembly operations such as part picking for kitting. A single-axis wrist offers speeds up to 3000 degrees per second. The M-1iA operates with the company’s latest R-30iA controller with integrated intelligent functions such as iRVision, Robot Link, and Collision Guard. 

 

The FANUC iRVision system is a ready-to-use robotic vision package, available on all FANUC robots, requiring only a camera and cable – no additional processing hardware. It has a 2D robot guidance tool to accomplish part location, error proofing, and other operations that normally require special sensors or custom fixtures. For robotic vision processes that exceed the capability of 2D vision systems, FANUC Robotics offers an integrated 3D vision system. www.fanucrobotics.com

 

Motoman introduced two new 3D vision tools. These 3D vision solutions were developed by Yaskawa Electric Corporation, Motoman’s parent company, to solve difficult automation applications. MotoEYE 3D, a PC-based hardware and software package, is used to locate randomly stacked parts to be picked up and placed accurately into a press or machine tool. The camera, mounted on the robot, takes images from multiple locations to evaluate and calculate the location of the part relative to a known location. The system uses 2D and 2.5D calculations to refine the search area, then uses a 3D algorithm to calculate the final location of the part. A Motoman 7-axis, in-line SIA20 robot with MotoEYE 3D demonstrated a machine loading process. Using MotoEYE 3D, the robot will locate stacked parts in 3D space, pick up the parts and load them into machines.

 

MotoSight 3D Advanced utilizes Azalea, a laser scan technology, developed by Yaskawa Electric. It features a high-speed CMOS vision sensor to quickly locate parts and report the position to the robot controller. A Motoman SIA10D robot integrated with MotoSight 3D Advanced demonstrated random bin-picking; the robot located and picked up parts to build a structure. Key to this demonstration is the speed of the scan and the almost continuous motion of the robot. Processing of this information is done rapidly, so that the robot can move to the next part without a long pause waiting for vision processing time. The unit is connected directly to the robot controller with a communication cable and power.

 

Motoman’s new RobotPro Web Edition provides a comprehensive web-based expert system for performing robot preventive maintenance, alarm-code troubleshooting, and repair procedures. Designed exclusively for use with Motoman robots that have NX-series controllers, the software is tailored to each specific robot model and is structured in a user-friendly format with well-illustrated, step-by-step procedures that are easy to understand and follow. Because it is web-based, RobotPro Web Edition does not require installation and is not tied to a specific computer. www.motoman.com

 

Schunk displayed a robot built from their innovative modular mechatronic robot components. Shunk has a wide range of modules to construct robots to meet many applications. A key component of this modular robot architecture in the PRL servo-electric rotary actuator modules that contain a brushless servo-motor with Harmonic Drive transmission, incorporating the complete power and control electronics. It is capable of positioning moves with ramp control and features monitoring of the end positions, voltage, current and temperature. The compact rotary actuators achieve an intrinsic-weight/load-weight ratio exceeding 2:1 since it is constructed of lightweight, high-strength materials. The PRL has a hollow shaft in the middle to run cables and the unit supports Profibus DP, CAN bus, RS-232, and CANopen interfaces.

 

Users create combined systems (e.g. a rotary gripping module) with various other modules using Shunk’s PowerCube series modules.   The Series PGN plus grippers, used for high temperature applications is an example.

 

 

Energid Technologies Corporation in cooperation with Schunk has released a version of their advanced control and simulation software, Actin, targeted for Schunk’s modular robotic arms.  The software removes the complexity involved in controlling the arms, allowing developers to focus on hand (or gripper) placement rather than joint placement. Since the software is generic, it can be used to control any configuration that can be created with Schunk modular components. Actin provides many optimized control strategies that can be cascaded to build control systems. www.schunk.com

 

ifm efector introduced a new 3D Image Sensor that measures size, shape and volume in industrial automation applications. The compact sensor uses time-of-flight distance measurement and photonic mixer device technology to identify an object in the sensor‘s field of view. An integrated 64 x 48 pixel array – in which each pixel represents a time of flight measurement – defines the field of view for the sensor.

 

The 3D sensor technology provides critical information in applications such as palletzing and de-palletizing, material handling, bulk level of materials and intelligent routing/sorting. ifm's 3D image sensor's receiver element is a System-on-Chip design. The complete sensor element and electronics are built on a 0.25 mm square silicon chip. This miniature chip enables 3D imaging using Time of Flight, and reduces the size of the sensor and its cost.   The sensor also includes patented Suppression of Background Illumination (SBI). This technology allows the sensor to eliminate the effects of external lighting such as sunlight and internal high-powered lighting. This allows the sensor to be used in almost any indoor or outdoor application. With a list price of $1450 (U.S.), ifm states that the 3D Image Sensor is a new benchmark for price and performance in 3D object detection. www.ifm.com/us

 

Sick introduced a new modular safety controller and new vision sensor.

 

SICK announced the launch of its FX3 Flexi Soft Modular Safety Controller. Flexi Soft is a software programmable, expandable, safety controller for a wide range of safety applications. The modular hardware platform expands module by module (12-144 inputs/outputs) and features a small footprint. Features include Fast Shut-Off, EFI and Network Communications (8 ms) and supports the following network communication: EtherNet/IP, PROFIBUS-DP, PROFINET, CANopen, Ethernet TCP/IP, and Modbus TCP. 

 

Hardware and software configuration of the Flexi Soft system is done via the Flexi Soft Designer, programmed with a function block based logic editor. Once a system is configured, it is then saved and stored in the memory plug. Up to 255 logic blocks are available. These logic blocks consist of general (AND/OR/XOR/NOT) blocks and application-specific (Bypass, Muting, Press) blocks. A comprehensive library of 32 certified function blocks is also available. In addition, the free software offers up to date diagnostics, simulation mode, error history reports, specific tag names, online monitoring and much, much more. The “Flexi Soft Designer” is downloadable at www.sickusa.com/flexi

 

The new Inspector I20 FLEX Vision Sensor provides new features including interchangeable lenses and an I/O extension module with up to 16 outputs. The I20 offers four different lens options to quickly alter the field of view based on the type of application. In addition, the I/O extension module enables users to program up to 16 outputs.

  

Allied Vision Technologies (AVT) demonstrated two FireWire Stingray cameras that combine the newest Sony CCD sensors with AVT’s intelligent Smart Features.

 

The Stingray F-125 is equipped with the new, high-sensitivity Sony CCD, the ICX445, with 1.3 megapixel resolution. Incorporating ExView HAD technology, the camera delivers an especially high light-sensitivity. Combined with Stingray electronics, the user can expect outstanding image quality. With its IEEE 1394b interface, the Stingray F-125 can deliver up to 30 frames per second at full resolution.

 

The Stingray F-504 camera is equipped with the new 5 megapixel Sony ICX655 sensor, with single-channel read-out. It delivers razor-sharp images for applications requiring a high degree of detail.

 

Each camera is equipped with two FireWire IEEE 1394b connections, allowing for integration into a multi-camera system using daisy-chain networking. Two copper connections or one copper and one glass fiber connection (Fiber Optic Version) are available to choose from. www.alliedvisiontec.com

 

Baumer introduced the TZG01 Digital 3D Cameras, designed to replace multiple camera systems and extend the potential applications of 3D object detection. Equipped with an integrated Time of Flight (ToF) sensor, these cameras deliver rapid spatial capture of objects and components. The cameras provide data on target dimensions and position with a single snapshot that captures and displays both a distance and a grayscale image.

 

At frame rates up to 54 fps the Baumer TZG01 Digital 3D Cameras offer a highly reliable acquisition range of 0.3 to 5 meters. These 3D cameras integrate lens, sensor, and LED into a compact, IP67-rated housing. The Baumer-GAPI, generic software programming interface enables integration into an application. The Baumer SDK includes all libraries, help files, and tools for camera control.

 

The cameras are equipped with a standard fast Ethernet that delivers data on cables as long as 100 meters. The camera also offers a single-cable Power over Ethernet (PoE) interface where both data and power run on a single Ethernet cable to reduce installation costs.

 

Baumer has introduced the new HX Cameras, a series of high-speed CMOS cameras that offer frame rates up to 500 fps and resolutions greater than 1.3 megapixels at 1280 by 1024 pixels. HX Series Cameras can deliver frame rates up to 120,000 fps by restricting image data to one, two or three regions of interest within the full frame. By supporting the CameraLink communication standard, the cameras can achieve guaranteed data transfer rates up to 680 MB per second.

 

HX Series Cameras provide exceptionally high photo sensitivity to 2500ASA, allowing high speed inspection even in low-light environments without the need for supplemental lighting. For highly dynamic applications containing very bright and very dark objects, the cameras offer an adjustment that resembles the non-linear dynamic response of the human eye. 

 

For environments with changing light conditions or outdoor machine vision applications, HX Series Cameras offer a multi-exposure capability that delivers enhanced images with up to seven accumulated exposures. Each exposure results in a corresponding image. www.baumerelectric.com/usa

 

Matrox Imaging introduced its new high-performance computing (HPC) platform for industrial imaging: Matrox Supersight e2. Matrox Supersight e2 offers OEMs significant performance and flexibility for machine vision and medical imaging applications that generate extraordinary amounts of data.

 

Applications such as semiconductor wafer and mask inspection, flat panel display (FPD) inspection, and CT scanning benefit from performance gains with Matrox Supersight e2 by leveraging multiple clusters of CPUs, GPUs and FPGAs. Matrox Supersight e2 provides an environment for considerable data and task-level parallel processing through the interconnection of CPUs, GPUs and FPGAs using a unique PCI Express® (PCIe®) x16 2.0 (Gen2) switched fabric that removes I/O bottlenecks between the multiple processors.

 

Applications for Matrox Supersight e2 are developed with the Matrox Imaging Library (MIL) and its Distributed MIL API. As MIL is supported on all Matrox Imaging hardware platforms, development on Matrox Supersight e2 is simplified and ensures the source code is portable across all devices, from nodes with 32 CPU cores and 4 FPGAs, to a node with 8 CPU cores, 1 FPGA and 6 GPUs and everything in between. www.matrox.com/imaging/en/