Motion Control

RICHARD VAUGHN | Senior Automation Engineer, Mechatronics

Bosch Rexroth Corp., Charlotte, N. C.
This Cartesian robot
consists of basic sys-

How to
tem building blocks
that were customized

Pick
later. With such designs,

the Right Robot

Robots automate
high-volume
manufacturing lines Six-axis robots move forward and back, up and down,
and can yaw, pitch, and roll to offer more directional control
as well as small- than SCARAs. This is suitable for complex movements that
scale operations. simulate a human arm reaching under something to grab
Heres how a part and place it on a conveyor, for example. The additional
range of movement also lets six-axis robots service a larger
Cartesian robots volume than SCARAs can. Six-axis robots often execute
compare with the welding, palletizing, and machine tending. Programming
other two types of their movements in 3D is complex, so software typically maps
the motion to a set of world coordinates in which the origin
robots. sits on the pedestals first joint axis.
PICKING BETWEEN ROBOT TYPES
To pick a robot, first evaluate the applications needs. That
starts with profiling the jobs load, orientation, speed, travel,
OEMs can design con-
trols and mechanical
components sepa-
rately and then tie them
together with custom
code for a timer to trig-
ger a pick-and-place
motion.
robots can place heavy payloads to within 0.1 mm, as the
weight deflects the arm and degrades the robots ability to
consistently position the load with accuracy. But Cartesian
robots with ball-screw actuators and well-spaced support
bearings can repeatedly place 50 kg and heavier loads to
within 10m.
2. Orientation depends on how the robot is mounted and
how it situates parts or products being moved. The goal is
to match the robots footprint to the work area. If a SCARA
or six-axis robots floor or line-mounted pedestal creates an
obstruction, then such robots may not be the best option.
If the application only needs movement in a few axes, then
small-frame Cartesian robots can mount overhead and out
of the way. But for intricate part handling or work needing
four or more axes of motion, a Cartesian robots framework

T
he use of Cartesian and six-axis robots, as well
as selective-compliance-articulated robot arms
(SCARAs) is on the rise. They automate tasks to
accelerate cycle times, increase throughput, and
eliminate bottlenecks. Advanced controls make the robots
user-friendlier than ever, with fewer backend-programming
requirements. And in some cases, online tools let end users
and OEMs quickly choose and configure robot features.
Cartesian robots, sometimes called gantry robots, are
mechatronic devices that use motors and linear actuators to
position a tool. They make linear movements in three axes,
X, Y, and Z. Physical scaffolding forms a framework that
anchors and supports the axes and payload. Certain applica-
tions, such as machining tightly toleranced parts, require full
support of the base axis, usually the X axis. In contrast, other
applications, such as picking bottles off a conveyor, require
less precision, so the framework only needs to support the
base axis in compliance with the actuators manufacturer
recommendations. Cartesian-robot movements stay within
the frameworks confines, but the framework can be mounted
This packaging design uses a robot that picks boxes off a high-
speed conveyor and places them on a pallet. The picker must extend
a full meter to grab the boxes and move them down to the floor and
onto a pallet, making for a cantilever situation. Therefore, a cost-
effective Cartesian robot makes the most sense. Robots of all types
are spreading to new and creative applications, but Cartesian robots
in particular are proliferating thanks to linear servomotors, modules,
standardized components, and operator-friendly controls that lower
cost and boost performance.
horizontally or vertically, or even overhead in certain gantry
configurations.
In contrast, SCARAs and six-axis robots typically mount
on a pedestal. SCARAs move in the X, Y, and Z planes like
Cartesians, but incorporate a theta axis at the end of the Z
plane to rotate the end-of-arm tooling. This makes SCARAs
good for vertical assembly operations, such as inserting pins
in holes without binding. However, the arm is essentially
a lever, and that limits SCARAs reach: The joints are load
points that need robust bearings and high-torque motors to
handle the loads when the arm extends.
precision, environment and duty cycle, sometimes
called LOSTPED parameters.
1. Load. A robots load capacity (defined by the
manufacturer) must exceed the total weight of
the payload, including any tooling, at the end of
the robot arm. What limits SCARA and six-axis This Cartesian robot is just
robots is that they support loads on extended arms. as reliable as SCARAs and
Consider a machining center that makes bearing articulating robots, which
assemblies of 100 kg or more. That payload exceeds have set parameters and
the capabilities of all but the largest SCARA or six- directions of movement. In
axis robots. In contrast, a typical Cartesian robot contrast, Cartesian robots
can pick and place such loads with ease, because its are reconfigurable so man-
support frame and bearings consistently support ufacturers dont have to
the entire range of motion. buy new equipment when
Even when a heavy load is within a robots capac- designs change.
ity, it can degrade accuracy. For example, picking
and placing 50-kg items is within the payload range
of both SCARA and Cartesian robots. But 50 kg is
at the upper end of a typical SCARAs capabilities,
so it will take more costly controls and components
to handle the torque. Whats more, typical SCARA

34 12.12.13 MACHINE DESIGN GO TO MACHINEDESIGN.COM 35

 Motion Control DieQua offers
Han-Modular more gearboxes
If you can dream it, you can build it. plus application experience to help
select the best one for your needs

End users can change a Cartesian robots mounting brackets,

Helical Gearmotors
actuators, motors, and controls to meet changing applica-
tion needs. For example, to accommodate new production 1-75 HP Capacity
Motorized or Adapters
requirements, an overhead-mounted Cartesian robot can Right Angle or Inline
change to a side mount. Shaft Mount Designs
Multi-Stage Ratios
Modular Design

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Worm Reducers
7 sizes, 28-110mm CD
Fret-free Connection
NEMA or IEC Adapters
Coupling Input
This Cartesian robot has controls that let
Aluminum Housings
operators safely enter the machine cage to 2-Side Worm Support
Build your dreams with the connection you can count on teach it coordinates for picking and placing
(sometimes just by pulling the end effector
Save space by combining different transmission media and contact types in one connector.
from point to point). That reduces training Planetary Gearheads
The Han-Modular ensures a durable and lasting connection - no matter how tough time for operators and reduces the need for Precision or Economy
the environment. Inline or Right Angle
engineers to alter machines already running.
40-155mm Frames
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Low Backlash
can pose too many obstructions, and a 1 and 2 Stage Ratios
small SCARA robot, sometimes requir- Lubricated for Life

ing just 200 mm2 of space and four bolts

on a pedestal, may be more suitable.
Another factor is part orientation.
SCARA and six-axis robots can rotate
parts, an advantage for handling parts
or tools at various angles and positions.
To get similar flexibility, some Cartesian
robots have subcomponents called feed
modules that move light payloads in
the Z axis. Typically, feed modules use
a ball-screw thrust rod to move parts
or tools along the Z axis in handling,
pick-and-place, and feed applications.
Cartesian robots can also incorporate
rotary actuators to provide additional
orientating capabilities.
3. Speed and travel. Along with load
ratings, robot-manufacturer catalogs
also list speed ratings. One key consid-
eration when choosing robots for pick-
and-place applications is acceleration
times over significant distances. Car-
tesian robots can accelerate at 5 m/sec
or more, rivaling the performance of
SCARA and six-axis robots.
Cartesian robots also make sense
Servo Worm Gearheads
when applications involve long spans. Thats because designers can quickly modify
3 Backlash Levels
and extend Cartesian robots as needed with modules to 20-m long. Speed and dis- Shafts or Hollow Bores
tance are further customizable by choice of belt, linear motor, or ball-screw actua- Single or Dual Outputs
tor. In contrast, articulating arms are typically predesigned for a given reach, such 11 sizes, 25-200mm CD
Capacity: 10-7000 Nm
as 500 mm, for example. 20,000 Hour Ratings
4. Precision. SCARA and six-axis robots have predefined accuracy ratings that
make it easy to determine their repeatability of movement. But these robots lock
designers into one level of accuracy at the time of purchase. End users can upgrade Spiral Bevel Gearboxes
Cartesian or gantry robots to myriad levels of accuracy by changing the actuator, 9 Sizes
even to 10 m, with a ball screw. For less accuracy and to cut cost, end users can 1-250 HP Capacity
swap in a pneumatic or belt drive and a different actuator for 0.1-mm accuracy. Low Backlash Option
Ratios from 1:1 to 6:1
Precision is key in high-end applications such as machine tooling. Those Carte- Output Shaft Options
sian robots need better mechanical components such as precision-machined ball- Machined Housings
rail tables and ball-screw actuators. For applications where SCARA and six-axis
robot arms cant maintain accuracy due to arm deflection, consider a Cartesian
robot with high-precision linear bearings. The bearing spacing minimizes deflec- Special Designs
tion so the end effector can be positioned more accurately. Add-On Options
Modified Dimensions
Although small work envelopes favor SCARA or six-axis robots, sometimes High Speed Applications
these robots complexity and higher cost are unnecessary. One example where Special Environments
Cartesian robots work better is in a high-volume medical-pipette manufacturing Special Duty Needs
Custom Designs
application. Here, a robot takes pipettes from a mold and inserts them into a rack
transported by a secondary automation machine. SCARA and six-axis robots are
viable because 0.1-mm accuracy is sufficient in this application. But deflection is
problematic when the robot handles smaller 3-mm pipettes. Plus, lack of room for

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12.12.13 MACHINE DESIGN GO TO MACHINEDESIGN.COM
Motion Control

a pedestal inside the cell favor gantry robots. high-performance seals can enclose many of the axes struc-
5. Environment. Two factors that dictate the best robot are tural components.
the working envelopes ambient environment and hazards in 6. Duty cycle. This is the amount of time it takes to com-
the space itself. A third consideration, whether a robot will plete one cycle of operation. Robots that run continuously
go in a clean room, is generally not an issue because all robot 24/7 (as in high-throughput screening and pharmaceutical
types are manufactured in clean-room versions. manufacturing) reach end of life sooner than those run-
The pedestals of SCARA and six-axis robots tend to be ning only 8-hr days, five days a week. Clarify these issues in
compact, which is handy with limited
floor space. But this may be irrelevant
if installers can mount the robots sup-
port frame overhead or on a wall. In INTRODUCING OUR NEW

XX SERIES
contrast, for applications with mechani-
cal interference, as when a robot must
reach into boxes to pull out parts, six-
axis arms are usually most suitable.
Six-axis robots typically cost more than
Cartesians, but the expense is justified if
GORTRAC STEEL CABLE / HOSE CARRIERS
theres no way to execute the application
without complex motion sequences.
Environmental factors such as dust
Standard version is lighter than XL6 model,
and dirt also affect robot selection.
while retaining similar unsupported spans
Bellows can cover SCARA and six-
axis robot joints, and different types 3 locking points provide free movement
of seals protect Z-axis actuators. For and increase strength in straight orientation
clean rooms using air purges, Cartesian Snap rings allow for carrier length adjustment
robots let designers enclose the linear
Self-cleaning link design expels debris from
actuators in an IP65 structure that min-
critical areas of the link during operation
imizes entry of water and dust. Plus,
Outer link height of 6" (152mm)

Bar width is customer specied

CROSSBAR OPTIONS

Round or at bolted aluminum crossbars

(round bar is standard)
PVC poly rollers can be added to crossbars
or vertical dividers using round bars
Formed steel at bars or custom machined
cable/hose bars
Optional custom window extenders provide
extra interior space, when needed

On this robot, standardized components

and diagnostics make maintenance less
of a hassle. Cartesian robots are configu-
rable so operators can also make basic
1-877-958-4997 email: sales@aaman.com gortrac.com
changes in the field.

GO TO MACHINEDESIGN.COM 39
Motion Control
advance, and get robots with long lubrication intervals and movements through path following and programmed speed,
low maintenance requirements to prevent aggravation later. acceleration, and deceleration parameters. The options are
entry-level and high-performance controls.
ROBOT PROGRAMMABILITY AND CONTROLS Entry-level controls are generally available only with Car-
The most-suitable robot for an application also depends tesian robots. These operate with three degrees of freedom,
on the requirements for controls and programmability. All which require less computer processing and programming
robot controls interpolate point-to-point, linear, or circular sophistication than robots with more axes and degrees of free-
dom. Here, controls typically convert
linear machine-movement sequences
into X, Y, and Z Cartesian coordinates.
However, a range of control options
gives designers a choice between lin-
ear or circular interpolation. So if an
application only needs point-to-point
motion to pick up paper cups, for
example then lower-level controls
suffice.
High-performance controls process
more degrees of freedom and convert
machine-joint coordinates to the world
coordinates necessary for complex rota-
ry or circular movements. SCARA and
six-axis robots usually have expensive,
proprietary controls capable of circular
interpolation and movement sequences
a justifiable expense when applica-
tions need complex profiling and path
tracking.
Preparameterized control packages
are another option. These come with
about 80% of the programming already
done. Predefined function blocks coor-
dinate the motion of several axes. A
software wizard tailors the program to
specific applications and key parameters
of the robot actuators, such ball-screw
pitches. Simplified robotic mnemonic
code lets the end user load and program
the logic to save time.
THE SMOOTH With this software, end users arent
locked into proprietary programs if
OPERATOR
they use a PLC that conforms to IEC
61131-3, which unifies the syntax
and semantics of PLC languages. This
means end users can use PLCs from
FOR ABSORBING VIBRATION AND SHOCK: different manufacturers and take their
OUR SERVOMAX ELASTOMER JAW COUPLINGS. pick of programming with ladder dia-
grams, function-block diagrams, struc-
tured text, instruction list, or sequen-
tial function charts. Or programmers
RW-AMERICA.COM THE COUPLING. familiar with object-oriented languages
40 12.12.13 MACHINE DESIGN
Engineers can design with expensive features such as proprietary controllers.
multiaxis Cartesian Execute complicated tasks and require more program-
robots (as well as sin- ming for complex motion patterns.
gle-axis setups) with Take up less space and weigh less to fit a predefined foot-
online selection and print while delivering a specified speed.
CAD tools that simplify Exhibit less rigid arm extensions, because they are built
sizing and specification. to be as light as possible to carry heavier payloads.
GORTIFLEX
MOLDED BELLOWS
AN EXCEPTIONALLY DURABLE BELLOWS CONSTRUCTED FROM
A TUBE OF PURE ELASTOMER OR ELASTOMER-COATED FABRIC,
FORMED INTO A COMPLETELY SEALED COVER
can program PLCs without ladder logic
or a proprietary language.
New capabilities in Cartesian-robot Excellent extended-to-retracted ratio for
controls bridge this gap and let design- a molded cover
ers program in high-level programming
Internal and external supports can be
languages such as C++ and Java. Then
provided for use at pressures up to 15 PSI
operators can make basic machine
changes to Cartesian robots. Function Stands up to ne powder, liquid or
blocks can be preloaded into drives, chemical spray, cutting oil, sand, metal
so even lower-level workers unfamil-
chips and other contaminants
iar with programming can handle pro-
gramming for simple pick-and-place Superior protection in outdoor environments
applications, for example. Todays Car- with exposure to moisture, ice, temperature
tesian robots can also communicate variations and ultra violet radiation
with vision systems, conveyor track-
ers, and other sensors via protocol stan- Great for prototypes or early production volumes
dards including Sercos, Ethernet/IP,
and EtherCAT, which reduces the cost No tooling fee for standard shapes
of controls.
A desirable solution for any industry machine tool, construction,
motion control, mining and energy, material handling, transportation
SCARA AND SIX-AXIS-
ROBOT FEATURES
Technological developments have
advanced all robot types in recent years,
but SCARA and six-axis robots:
May come equipped to meet defined
speed and motion specifications
and deliver higher performance right
out of the box. 1-877-958-3992 email: sales@aaman.com gortite.com
May cost more because they come
GO TO MACHINEDESIGN.COM 41
Motion Control

Come prebuilt for specific perfor-

mance ratings (compared to Car-
tesian robots that designers can
scale or tailor to specific needs).

CARTESIAN-ROBOT FEATURES
Cartesian robots total cost
of ownership has decreased 25%
over the last five years due to pre-
parameterized control packages,
online design tools, and economies
of scale. So now they are viable Feed modules like the
options for small to midsize manu- R e x r o t h V K K p r o v i d e
facturers looking to automate stor- SCARA-like control for
age-and-retrieval, pick-and-place, moving lighter payloads on
liquid-dispensing, packaging, and a Cartesian robots Z axis.
auxiliary machine-tool operations.
In addition, Cartesian robots:
Consist of standardized compo-
nents that combine into robots
that cost less than purpose-built
robots. This lets end users quickly
assemble robots piece by piece
rather than customize machines
for ever y application. In
some cases, standardized
mounting brackets with cen-
tering rings replace traditional
dowel pins on module guideways
to further simplify assembly.
Can be specified with online tools.
Online software takes some of the
confusion out of how to leverage
the mix-and-match modularity of
Cartesian robots. It lets engineers
plan linear motion for single or
multiaxis automation by enter-
ing the mass to be moved and the
required stroke. In the past, designers ordered Cartesian-robot subcomponents
using individual part numbers from different vendors. Now, engineers can often
order integrated robot modules including rails, servodrives, mechanical ele-
ments, and controls with one vendor part number.
Are safer. On legacy Cartesian robots, safety circuits connect to controls that
introduce delays as they command the motors drive amplifier. Newer robots have
intelligent servodrives instead, with safety circuits that accelerate response. These
circuits also let Cartesian robots operate in reduced-torque mode, similar to the
teach mode of SCARAs and six-axis robots. These
modes let operators enter the robots safety cage and RESOURCES
manually teach the robot coordinates to get a job Bosch Rexroth,
done. To prevent injuries, robots in this mode shut www.boschrexroth-us.com
down if it contacts the trainer.

12.12.13 MACHINE DESIGN