ABB's FlexLoader M robot family brings modularity to machine tending
ABB has released a new family of modular machine tending cells for the metalworking industry, aimed at maximizing flexibility and machine utilization while minimizing productivity losses caused by unplanned production stoppages.
The FlexLoader M robot family, consisting of six different versions, offers different ways to unload and load machines depending on the size, shape and number of parts being processed, making it ideal for applications such as foundries and injection molding operations producing several product types in varying quantities.
Key features of FlexLoader M cells:
- intelligent robotic cells for machine tending with standardized modules allow easy expansion to meet changing needs
- flexibility to meet a range of requirements, with new parts commissioned in just minutes
- simple vision-based programming removes the need for specialized skills and increases equipment utilization
“As customers demand greater variety and shorter lead times, metal producers need a production process that can respond quickly and offer the flexibility to handle large-scale production, small volumes and single-batch production. FlexLoader M accelerates this shift by providing a single unified platform for machine tending, delivering the flexibility needed to meet a wide range of production requirements, along with productivity gains from reducing the time, costs and disruptions traditionally associated with production changeovers”
The launch starts with several tray and conveyor options, with other variants to be released in the coming months. The FlexLoader M conveyor uses a simple yet powerful vision system that makes it easy to load workpieces of complex shapes, providing the flexibility to handle different workpieces with a single cell.
FlexLoader M Tray is a slide-out drawer that makes machine tending easy. With a minimal footprint that allows it to be placed almost anywhere, it is ideal for handling various parts of different shapes, such as cubes, cylinders, plates and tubes.
FlexLoader M with standardized interchangeable modules offers a flexible and expandable solution for a wide range of machine tending applications, including lathes, milling machines, CNC machines and machining centers. A key advantage is the ability to use the same base machine while swapping incoming and outgoing feeding modules as requirements change. The modular approach of FlexLoader M simplifies upgrading and scaling, as installation and commissioning take only one to two days on average.
FlexLoader M meets manufacturers' need for a simple automated solution that produces more parts in less time. FlexLoader M robotic cells are extremely easy to use and can be programmed quickly, even without specialized robotics knowledge.
The robot family allows new parts to be programmed in less than five minutes without any machine vision programming skills, while switching between already programmed parts takes less than one minute, making single-batch production a reality. The simplicity of the software means full operator training can be completed in less than half a day, further reducing the time needed to commission the cell.
FlexLoader M can reduce labor costs for machine tending processes by up to 90%, with one operator able to handle up to 10 cells simultaneously. The automated system achieves machine utilization above 97%, compared with 40-60% for manually operated machines.
All versions can be equipped with a vision system that determines the position of the workpiece and sends commands to the robot, machines and other equipment, such as air cleaning stations, marking, polishing and measuring systems. The vision system can use either a 2D camera or a 3D sensor, depending on the application.
FlexLoader M also includes data-driven optimization features, including remote monitoring that allows operators to monitor, troubleshoot and optimize their robotic systems, while its vision software provides additional functions, including condition monitoring, fleet management, and performance and order management.
FlexLoader M will replace ABB's current FlexLoader cell family, which has proven to deliver reliable and predictable results. Delivering benefits including higher machine utilization and the ability to run reliably without human intervention, FlexLoader cells have proven capable of delivering a much faster return on investment, giving users a sustainable competitive advantage.
