Fachartikel / Professional article
Robot operation easier than ever before
In cooperation with PNEUMOTEC, the user interface of a KUKA robot is displayed directly on the controller of an OKUMA machine tool.
Machine tools work with CNC controllers, while industrial robots work with robot controllers. This is necessary, as these devices place completely different demands on the control algorithms and functions. Until now, in order to control robot-automated machine tools, the operator had to carry out entries on two separate operator control panels. The main entries for operation of an automated system are made on the machine tool controller. It thus makes sense to integrate operator control of the robot into the user interface of the machine tool. PNEUMOTEC, in Issum, received an order from the European headquarters of machine tool manufacturer Okuma to equip an LB3000 EX lathe with a KUKA robot. An obvious approach was to exploit the fact that the user interfaces of both the Okuma machine tool and the KUKA robot are based on Windows XP. This enabled simplification of work for the operator and implementation of operator control of the robot from the control panel of the machine tool. Direct display of the graphical user interface on the control panel of the machine tool The interface was implemented using the HMI (Human Machine Interface) option package from KUKA. This software makes it possible to create a user interface from existing modules and to link them to functions of the robot controller. This HMI option package has already been used for many years by KUKA customers to provide a graphical representation of input masks and operator control elements for KUKA robots. These graphical user interfaces are normally
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displayed directly on the operator control device of the robot, the KCP (KUKA Control Panel). The new feature of this joint development by Okuma, PNEUMOTEC and KUKA Roboter is the direct display of the graphical user interface on the control panel of the machine tool. The connection between the machine tool and the robot is established via Ethernet an interface that comes as standard with both the Okuma machine tool and the KUKA robot and thus offers a cost-effective solution. The first step was simply to make work easier for the operator: a few functions on the machine tool user interface sufficed to control all necessary entries for the robot. For the robot, the operator only requires basic functions, such as Start / Stop, Cancel, Move to service/home position and, under certain circumstances, program selection.
The user interface is displayed directly on the controller of the OKUMA machine tool
Simple operation without knowledge of robots The operator can thus operate the robot automation system via remote control from the machine tool control panel; with absolutely no knowledge of robots, he can move the machine to a service position for a tool change, for example, with a simple touch of the touch screen. Program execution at the original position can then be resumed by touching the screen again.
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Advanced operators have the opportunity of calling the parameter list to modify component dimensions or enter the desired setdown point directly in the machine as values in a mask, thereby influencing the robot program.
Parameter list
The hardware of the automation cell has been implemented by PNEUMOTEC as a rotary indexing magazine with a capacity for 18 blanks and finished parts. Depending on the machining time per workpiece, the machine can work for up to an hour without intervention by the operator. If required, the rotary indexing magazine can be effortlessly converted to different part lengths and diameters. In this way, the simplicity and flexibility of the user interface are also optimally reflected in the mechanical components and the operator can control the automated system without the need for extensive training covering a wide range of different workpieces. The high degree of flexibility and simple operator control allow high utilization and availability of the automation system, resulting in a payback period of significantly less than a year in most cases.
Author: Andreas Schuhbauer, Key Technology Manager for machine tools at KUKA Roboter GmbH
PNEUMOTEC GmbH & Co. KG Automatisierungstechnik, a medium-sized company in the Voortmann Group, has developed over the years to become one
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of the leading specialists for custom-tailored system solutions in the field of special machines and automation equipment. At the companys site in Issum am Niederrhein, measuring some 13,000 m2, PNEUMOTEC employees develop, design and manufacture complete solutions for industrial production processes in a wide range of sectors. The name Okuma is synonymous with a broad range of high-tech CNC machine tools for turning, milling, drilling and grinding applications. Okumas worldwide success is due to the high quality and reliability of its products, even after many years in operation. Okumas European headquarters is located in Krefeld. It supports 34 official dealers in Europe, Africa and Israel.
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