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Applications for Robotic Machine Infeeds

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Overview

Packaging machinery infeed and discharge speeds can affect productivity in primary and secondary packaging scenarios. Infeeds that fail to keep pace with the equipment's production capabilities create costly unscheduled downtime while the machine waits for product. Improperly fed or discharged product will also cause a high speed packaging machine to jam, which stops the system and potentially causes damage to the product or the machine. The ESS TaskMate Robotic Machine Loading/Unloading System integrates with existing or new packaging lines to increase system flexibility and productivity. The system comprises a FANUC robot, custom ESS-designed end-of-arm tooling (EOAT), controls, programming, and guarding. The performance and reliability of TaskMate robotic systems assure a fast ROI and years of service.

Monoblock Fillers/Cappers

Cartoners

Case Packers

TaskMate(R) Robotic Systems

Medical Device Assembly Systems

Pallet Cells/Depalletizers

OEM Equipment

Custom Designed Equipment

System Integration

Track and Trace Integration

Turnkey Services

Machine Videos

Application Notes

Types of Infeeds: Hard Automation vs. Robotics

Hard automation refers to a sequence of processes and movements determined by equipment which has been designed to perform a single function, usually for a single product. This specialized design comes with a high equipment cost, and changeover to handle different products presents significant downtime for the packaging line. Annual and routine maintenance associated with replacing wear parts can also affect overall cost. Failure to install the correct parts or align them properly results in additional downtime, scrap and re-work. Flexible automation typically refers to robotic systems. These systems produce small to medium batches of products; each new batch, depending on product design, may require a simple change of robotic end-of-arm tooling and programming programming is usually performed in seconds via a human-machine interface (HMI). Changeover times are typically under 5 minutes for a robotic system.

Flexible automation typically refers to robotic systems. These systems produce small to medium batches of products; each new batch, depending on product design, may require a simple change of robotic end-of-arm tooling and programming programming is usually performed in seconds via a human-machine interface (HMI). Changeover times are typically under 5 minutes for a robotic system.

Robotic Loading of a Blister Packaging Machine Hard Automation Inspecting Test Kits Combined Hard and Robotic Automation
Robotic Automation Loading a Blister Packaging Machine Hard Automation Fixture Handles Test Kits During Vision Inspection Combined Hard and Robotic Automation for Collating and Machine Loading
Specifications  
Speed Up to 120 cycles per minute (varies by robot)
EOAT Vacuum or Mechanical Gripper
Changeover Time 15 Minutes Typical
Standard Voltage 220V, Single Phase, 60Hz (other voltage options available)
Dimensions 30" L x 30" W x 78" H (typ., varies by application)
762mm L x 762mm W x 1981mm H
Product Types Bottles, Jars, Tubes, Pouches, Sachets, Cartons, Blisters
Features
  • Controls and Programming
  • Interlocked Safety Guarding
  • Custom End-of-arm-tooling (EOAT)
  • Fast, Tool-free Changeover
  • Small Footprint
  • Options
  • Vision Inspection
  • Line Tracking
  • Clean Class Robot Option
  • Complete Integration with Existing Equipment
  • Extended Warranty for Robot
  • Robotics Training

  • System Description

    ESS Technologies, Inc. TaskMate(R) Robotic Machine Loading/Unloading cell incorporates a FANUC robot and custom EOAT to create a flexible, high speed robotic cell ideally suited to load and unload high speed packaging machinery. The system can be integrated with most any packaging line to operate as a high speed product loader or unloader for cartoners, thermoformers, blister packaging machines, tube fillers, baggers/pouchers, wrappers, etc. Whether installing a new packaging line or retrofitting an existing line to improve performance or accommodate a new product, ESS Technologies is an authorized FANUC system integrator with the expertise to design and integrate robotic infeed systems. ESS has designed and deployed numerous system that integrate FANUC robotics with cartoners, tube fillers, and wrappers from other OEMs.

    Real World Applications with FANUC Robotics

    Robotic Loading of a Blister Packaging Machine Robotic Loading of a Poucher Infeed Robotic Loading a Blister Packaging Machine
    M-10iB Loading Batteries into Blisters at the Infeed of a Blister Packaging Machine M-430iA Loading Diagnostic Test Kits Into a Poucher Infeed   LR Mate 200iC Loading USB Drives in a
    Blister Packaging Machine
    Robotic Collating and Loading of a Cartoner Infeed Robotic Loading of a Blister Packaging Machine Robotic Loading of a Thermoformer Machine
    LR Mate 200iB Collating and Loading Blisters of a Drug Delivery Device Into the Infeed of a Horizontal Cartoner M-430iA Loading Breath Strips into Blisters at the Infeed of a Blister Packaging Machine M-6iB Loading Drug Delivery Devices into a
    Thermoformer Machine
    Robotic Vacuum EOAT for Multiple Picks Robotic Gripper EOAT for Single Pick Robotic Hybrid Vacuum/Gripper EOAT
    EOAT for Picking Multiple Products
    (vacuum-style)
    EOAT for Unloading Test Tubes from Assembly
    Pucks (gripper-style)
    EOAT for Cases of Various Sizes (hybrid
    vacuum- and gripper-style)
    Robot Model Robot Description Robot Features
    M-1iA
    • Four (4) or Six (6) Axes
    • Payload 1.1 lbs (0.5kg)
    • Reach 11" (280km)
    The M-1iA is a lightweight and compact high speed assembly and pick-and-place robot. The small size allows the robot to be installed in a narrow space. The drive unit can be integrated into a machine, or the robot may be ordered with a desktop stand or a reverse stand for mounting the robot upside down.
  • Can Integrate Directly with Packaging Machines
  • Desktop and Reverse Robot Stands Available
  • Camera Port Easily Integrates Vision Capabilities
  • Super Light Link Enables High Speed Motion
  • R-30iA Controller
  • M-3iA
    • Four (4) or Six (6) Axes
    • Payload 13.3 lbs (65kg)
    • Reach 53" (1350km)
    The M-3iA intelligent, parallel-link robot is designed to maximize speed and flexibility for assembly, small part handling and picking applications. The robot is ideal for medical devices, pharmaceuticals, and cosmetics.
  • Optional Cooling Fans for J1, J2 and J3
  • Super Light Link Enables High Speed Motion
  • Hollow Wrist for Easy Utilities Routing to EOAT
  • R-30iA Controller or R30iA Mate Open Air Controller
  • LR Mate 200iC
    • Six (6) Axes
    • Payload 11.1 lbs (5kg)
    • Reach 27" (704mm)
    The LR Mate 200iC electric servo-driven mini-robot is tabletop size, and features a slim arm profile, light weight design, making it ideal for a number of commercial applications. When used with the R-30iA Mate Controller, the robot supports a variety of intelligent functions including iRVision , built-in vision-ready controller and force sensing.
  • iPendant Internet Ready Teach Pendant
  • 360 J1 Axis Rotation
  • Fail-safe Mechanical Brakes on All Axes
  • Extended Network I/O Capabilities: I/O Link, DeviceNet, Profibus
  • 7m or 14m Connection Cables
  • M-10iA
    • Six (6) Axes
    • Payload up to 22 lbs. (10kg)
    • Reach up to 64" (1632mm)
    The Model M-10iA series offers high speed and high performance. Along with FANUC's iRVision integrated vision package in the controller, the M-10iA comes vision ready with a 2DV cable integrated through the robot arm as a standard option.
  • iRVision for Guidance and Inspection
  • Up to 40 Axes (robot+auxiliary) on Same Controller
  • Extended Communications Capabilities: FTP, DeviceNet, A/B RIO, Profibus, Genius, CC-link, etc.
  • Linear or Circular Conveyor Tracking
  • 14m or 21m  Connection Cables
  • M-20iA
    • Six (6) Axes
    • Payload up to 44 lbs. (20kg)
    • Reach up to 79" (2009mm)
    The Model M-20iA is designed with a hollow arm and wrist to permit utilities to be neatly contained within the robot arm. To complement the built-in vision, the M-20iA has an integrated vision cable from the J1 base to the J3 interface panel, greatly simplifying the addition of vision to the application.
  • Up to 40 Axes (robot+auxiliary) on One Controller
  • Extended Communications Capabilities: FTP, DeviceNet, A/B RIO, Profibus, Genius, CC-link, etc.
  • Linear or Circular Conveyor Tracking
  • 14m or 21m Connection Cables
  • iRVision System Delivers High Performance 2-D and 3-D Machine Vision Capabilities
  • M-430iA
    • Five (5) Axes
    • Payload 4 lbs. (2kg)
    • Reach 35" (900mm)
    The Model M-430iA is optimized for high speed picking and packing. The electric servo-driven robot is supported by the intelligent robot control system and can work with FANUC's high speed visual tracking.
  • Flexible Cable Placement
  • Line Tracking and Visual Line Tracking
  • Supports Industry-leading Software Package for Multiple Robot Setup
  • iRVision System Delivers High Performance 2-D and 3-D Machine Vision Capabilities
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    ESS Technologies, Inc.
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    FANUC System IntegratorMember - PMMIAssembled in the USA




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    Phone: (540) 961-5716 • Fax: (540) 961-5721
    Contact ESS Technologies, Inc.
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