Assembly Order Picking with Two Robots on a 13 Metre Traversing Axis

One of Ulrich Rotte’s showcase projects involved assembling gate controls for the door and gate specialists Hörmann, incorporating manual and automated processes for both current and legacy products. Robots, guided by a 3D Vision System, handle order picking and assembly, ensuring precise operations without compromising safety. Ulrich Rotte developed and built customised grabbers for the different tasks that the robots are taking care of.

Two FANUC M-710𝑖C/45M robots at Hörmann’s Salzkotten factory take parts from prepared large load carriers from a total of 14 spaces. They are then laid on workpiece carriers. Handling reusable packaging and preparing it to ensure it can be returned is also part of the task. It is possible to select manual or automated supply and disposal of order picking.

14 places means that the robots have long paths. Therefore, both FANUC robots have been assembled on a 13 metre long linear axis. Robot 1 approaches spaces 1 to 7, robot 2 approaches spaces 8 to 14. So long as the robots do not travel beyond their respective borders, “Dual Check Safety” (DCS) software offers sufficient protection. Another safety option from FANUC, “Interference Check”, prevents the robots from colliding with one another in dynamic operation.

A 3D Vision System delivers the position information required for grabbing and also determines information on the fill level of the respective load carrier. Project manager Daniel Bürgermeister reports: “It is significantly easier to work with a system in which CAD models are stored instead of defining image features which have to be checked each time. I’m not a programmer, and I was able to operate it within a few minutes.”

The workpiece carrier with all the parts required for the assembly take the product through the entire assembly process. A final inspection at the automated test station is supported by two type LR Mate 200𝑖D robots that simulate different operating procedures.

After passing the test, controls move to Hörmann’s storage facility for final assembly. Since range is important for this task, a long-arm M-20𝑖A/12L FANUC robot applies lids and type plates, verified by image recognition. If approved, controls are placed in a load carrier and moved by a Rotte conveyor.