Automation IG’s SuperCell pushes the envelope of robotic integration by combing four robots on one controller. Overcoming limitations in robot controllers and communications technology, Automation IG’s SuperCell:

• Integrates 3 weld cells and 2 material handling projects together into one system together with inspection, machining and weld monitoring.
• Provides superior control of the manufacturing process and part quality.
• Safely provides continuous power to welding tools with Automation IG's patent-pending electrical system.
• Completely utilizes welding robots so that the operator does not lose time waiting to recharge a fixture.
• Reduces the burden on maintenance and other critical plant staff with its easy-to-learn, easy-to-use interface.

Automation IG’s unique concept combines the ABB IRC5 controller, high-capacity material-handling robots, and the RobotStudio offline-programming package into the SuperCell – a revolutionary new system that can meet high production goals with little to no operator downtime and still maximize floor space.

One of the nation’s leading motorcycle manufacturers needed to produce crucial parts in-house while still maximizing the production value of each square foot of floor space.  Traditional weld cells could not meet production goals and required too many operators. Flexible weld cells from other vendors proved unreliable and inadequate. Automation IG had to meet three main criteria in designing the SuperCell:

• All value-adding machinery had to be utilized efficiently at all times.
• The welding robots had to be in continuous use.
• The operator could not be kept waiting to recharge the fixtures.

Using three fixtures and only two operator loading stations, Robot Team Manufacturing ensures that at least one fixture is always in transit or on standby between loading and welding. As soon as the welding on one fixture is complete, another is waiting to take its place. When the operator is finished loading one fixture, the next is waiting to be unloaded and recharged. Two subassembly fixtures make one final fixture for a complete tooling set. The third handling robot unloads the finished weldment inside the cell, sparing the operator from heavy manual unloading. The location of each and every final weldment within the manufacturing process is completely controlled.

Combining two units of two robots each, the SuperCell employs four robots – two welding and two handling. An Automation IG Weld Monitor attached to each welding robot monitors every weld. An additional handling robot removes the finished part to a cooling rack prior to machining. The same robot then moves the finished piece from the cooling rack to a machining center, from the machining center to a drying station, and then either to an overhead conveyor to the paint room, an in-cell conveyor for special parts, or to a custom CMM inspection station.

To achieve production goals, Automation IG installed a standard Y-cell weld cell between operator stations to pre-weld small components. The SuperCell can automatically transfer tools from one side to the other mitigating possible downtime. Automation IG's tooling concept allows for manual operation for producing service parts in the future.

The final enabling components were ABB’s RobotStudio software and Automation IG's control package. Prior to powering on the robots, our software engineers and robot programmers completed and tested the entire robot program. Programming the system during the design phase rather than the building phase allowed Automation IG to meet tight deadlines and resolve design issues early.

Automation IG provides a flexible tooling system with our patent-pending design that simultaneously provides continuous power and tooling communication – something other vendors cannot do. Where other systems limit the fixture to elaborate end effectors, Automation IG's unique controls solution provides continuous power, air and communications to the tool whether it is docked at the operator, at the robot or transitioning between the two.

Additionally, Automation IG installed a smoke-eater feature, reducing power and maintenance costs. Request-to-enter boxes ensure a safe, recoverable state for maintenance, minimizing time lost to maintenance. A custom CMM machine measures finished parts to ensure the continuous quality of components coming off the system. Automating a majority of the quality controls saves considerable time and resources.

A series of OI-15 industrial HMIs installed at each operator station control the entire system. The screen’s unique features provide quick trouble-shooting information complete with tooling pictures, station information, and process status. Automation IG’s controls engineers automated the entire system and designed the interface to give operators and maintenance the tools necessary to run and maintain the system with minimal training.

Some key features of Automation IG’s SuperCell are:

• An ABB IRC5 controller that allows four robots to synchronously move and weld.
• ABB high-capacity material-handling robots with a 500 kg capacity.
• True robot-as-positioner with dedicated tooling.
• ABB RobotStudio offline programming software.
• Automation IG controls allow continuous tool power and communication.
• Automation IG’s Robot Team Manufacturing concept combines dual robot handling, three fixtures, and two load stations.
• A finished-part robot to integrate material handling system improves control of finished part process.
• A custom CMM station continuously measures finished parts to catch any quality issues early and free customer quality engineer resources.
• Automation IG Weld Monitors quickly and automatically identify weld quality issues so that fewer parts are scrapped.
• OI-15 – Automation IG’s industrial HMI provides a complete, operator and maintenance friendly interface for all cell functions.