Retooling of robot systems for alternating workpiece designs

Requirements and solutions

Retooling processes on robot systems are necessary to handle changing workpiece and production versions. But each of these processes lead to unproductive times, entail a high error potential, and require additional knowledge and training.

Thus, good concepts for minimizing set-up times are, first of all, a business necessity to influence productivity as little as possible.

This article examines technical aspects and solutions to be considered for the development of efficient set-up concepts and has a look on the question where in an automation system component change must be addressed in order to achieve this goal.

First, there is the actual robot sequence program. Once created for a new version, it only needs to be started when the version returns. Setting up a new component for the first time is easy thanks to the flexibility and free programmability of a robot. Depending on the robot, it may not even be necessary to intervene in the robot program. Then, only the parameters of a new workpiece are transferred, and the robot sequence program is designed accordingly.

For workpiece-guided processes (i. e. the workpiece is moved by the robot), it is the gripper tool which must be retooled. In the case of tool-guided processes, the workpiece holder in which the workpiece is provided is affected. There are various options and strategies for retooling the tool (often a gripper tool), depending on the frequency and budget of this process. The most cost-effective solution includes exchangeable or adjustable gripper jaws. In this case, these are designed as interchangeable parts that can be changed using screws or quick- release fasteners or can be adjusted in stages or continuously.