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FANUC Collaborative Robot Technology and GM Applications Greg Buell Fanuc America Chris Ihrke General Motors
FANUC Collaborative Robot Technology and GM Applications
Greg Buell Fanuc America Chris Ihrke General Motors
Spare Tire Application • Perennial ergonomic
and safety concern • Productivity issue • Wanted a low impact
automated solution • Interested in using a
collaborative robot, but reach and payload requirements were outside the capabilities of available products
“Before”
Robot Specification • Payload capabilities • Passive safety features • Active safety features • Configurability
Payload Capabilities
Initial Requirements • Collaborative robot with
payload specification to handle spare tires
• Wrist load ratings capable of standard industrial tooling
• Reach ability to be able to stack the tire carts
Passive Safety Features
Pinch Points
Brackets and sharp edges
Color
External Considerations • The robot had to have a
visual distinction from other robots in the plant
• Standard robot features needed to be safeguarded against
• Inherent industrial robot hazards needed to be mitigated, pinch points, hard casing, etc
Distinct Green Color and soft foam
Pinch Points Eliminated
Active Safety Features
Collaborative Mode Maximum 250mm/s
Built-in Safeguards • Speed limited to 250mm/s in
contact stop mode • Multiple contact stop force
settings can be adjusted on the fly
• Push-to-escape on J1 and J2 for operator interaction
• Hard contact retract feature to help relieve quasi-static force
Stop
Push J2
Push J1
Retract
Configurability
System Configuration • Multiple contact stop force
settings • Ability to change forces based on
safety inputs or specific cell locations
• Push to escape force and speeds configurable
• Monitoring I/O for the safety features for cell awareness
• Payload change limits for safe part picking/dropping
Safety System Architecture • Safety rated force monitoring • Integrated into DCS • Third party certification
Safety Rated Force Monitoring
Collaborative Sensor • Safety rated collaborative sensor
mounted inside the robot • Active force reading as well as
current setting indicator • Internal checking system
constantly monitoring the sensor for correct performance
DCS Integration
Dual Check Safety • Collaborative Robot settings
integrated into DCS • Category 3 PL.d safety rated • All configurations are password
protected • DCS Broadcast safety signature
includes collaborative settings for plant wide safety monitoring systems
• DCS is TUV certified to meet industry standards
3rd Party Certification
Force and Power Limiting • TUV certified to meet a maximum
contact stop force setting up to 150N • Testing according to
• 2006/42/EC • ISO 10218-1:2011 • EN ISO 13849-1:2008 (CAT3,PLd) • IEC 61326-3-1:2008
Other Hazards • Gripper
– Soft covering – Extended diameter – Finger details retract into cast
rubber “bumper”
• Gravity – Monitoring of cart in position – Monitoring of stack height – Cross-checking of stack counts
with sensor measurements
• Trip Hazards
Spare Tire Application • Video – 1:05 from Fanuc, 0:25 from Orion
Spare Tire Application
Source: Alex Knapp Forbes Magazine, May 2015 Photo by Jonathan Kozowyk
“Some unlucky human at GM’s Orion, Mich. assembly plant has had the dull, backbreaking job of pulling spare tires off a conveyor and stacking them based on their assigned vehicle. …The factory’s first collaborative robot, which arrived in January, was ordered to stack tires. …The robot is now considered part of the team.”
GENERAL MOTORS Getting closer to the machine
Other Applications • Target positioning
– Active safety – Headlight
• Hot glue dispensing • Vision inspection • Fastener torqueing
Expanding Product Line
• 7kg & 4kg Payload • 550, 717, and 911mm reach • Integrated intelligent features(iRVision, Force
Sensing, networking, full I/O capability) • Born from real industrial robots capable of
real industry tasks • IP67 standard for the robot arm • Mobile cart ready, can run on 120v single
phase power • Light weight mechanical unit <30kg • Ceiling, wall, and floor mount
Contact
Greg Buell Senior Engineer, Collaborative Robots Fanuc America Corporation Rochester Hills, MI USA +1 (248) 377-7075 [email protected]
Contact
Chris Ihrke Senior Manufacturing Engineer, Advanced Automation Technology General Motors Warren, MI USA +1 (248) 640-8877 [email protected]
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