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Cartesian robots offer the same quality, reliability, speed and return on investment benefits as SCARA or articulating robots, with many possibilities for customization.
Once found mostly in manufacturing environments with extremely high volumes, robots are now being used in smaller organizations and in a wider variety of applications. The cost of implementing robotic systems has fallen significantly, plus it is now easier to apply robotics in more ways. The reason is simple: Over the last few years, controls have become more user friendly, requiring fewer programming resources. System design has become easier with the availability of online tools to help end-users and OEMs build systems directly. Servicing has also become easier and faster thanks to standardized components and powerful diagnostics.
These developments have come at a critical time. Small- and medium-size manufacturers in developed economies are facing increasing global competition. Advances in today's robotics are delivering competitive advantages that help them survive and thrive.
More applications, less cost
The use of robotics is justified in more applications because the cost/benefit ratio has become extremely attractive. For all robot system types, implementation costs have fallen dramatically, but especially for mechatronic systems in the form of multi-axis Cartesian robots. Standardization, modularity, and economies of scale have made Cartesian robot systems more affordable for more applications. Those factors, in conjunction with reductions in engineering, have allowed total cost of ownership prices to drop by up to 25 percent over the last five years. Plus, Cartesian robots offer the same quality, reliability, speed, and return on investment benefits as SCARA or articulating robots, with many possibilities for customization.
These benefits are encouraging smaller companies to explore the use of robots in new applications. This is especially true of Cartesian robots, which are already being used in a wide variety of applications such as automated storage and retrieval, pick and place, liquid dispensing, packaging, machine tool auxiliary operations, and many more.
The creativity of Cartesian robot users is boundless. During the recent recession, companies found ways to reinvent themselves, and people who never used Cartesian robots before created new applications. Unlike a six-axis or SCARA robot that can't be repurposed and has an established set of parameters and direction of movement, a Cartesian robot can be easily reconfigured. To accommodate changing production requirements, an overhead-mounted Cartesian robot could be changed to a side mount or flipped in a different direction. This flexibility makes it possible to rebuild machines instead of buying new equipment.
Once found mostly in high-volume manufacturing operations, robots are now being used in smaller organizations and in a wider variety of applications.
Making the best robotics choices at the best price
Because of the many robotics options, end-users sometimes face a dilemma in choosing between entry-level and high-performance features. People have different perceptions of how to define performance, speed, power, or expensive controls.
The best approach is to use a defined set of sizing and selection criteria to determine the required robotics feature set. This makes it possible to create a highly tailored robotic system that performs at exactly the right level and at the best possible price. The evaluation criteria include: Load, Orientation, Speed, Travel, Precision, Environment, and Duty cycle. We call this "LOSTPED."
One common misconception is to think that you need to buy a robot fully equipped with high-performance features. That is inevitably the case with SCARA and six-axis robots, where you tend to see "feature overkill." But with a Cartesian system, building blocks for a basic system can be purchased and then later customized. Mounting brackets, actuators, motors, and controls can be changed as application needs change.
Cartesian system mounting brackets, actuators, motors, and controls can be changed as application needs change.
There are pros and cons to this approach. The compact size of a SCARA robot might be more suitable for work inside a tight envelope. But if you have adequate space, a simpler Cartesian system can often be pre-built without having to purchase all the extra features included in a SCARA or six-axis design.
Moving from an entry-level to a high-performance feature set brings improvements in precision, cycle times, and application capabilities. High-performance controls, for example, provide circular interpolation capabilities. That is a true high-performance capability, requiring sophisticated and expensive control features. However, if the application only requires point-to-point motion (to pick up paper cups for example), that level of accuracy is not needed; a lower-level control can be used on the same robot to save money. High-performance mechanical components in a machine tool may require the accuracy of precision-machined ball rail tables. They will cost more than a less-precise compact linear motion module that's geared toward pick-and-place applications. A case-by-case LOSTPED evaluation will determine the best combination of performance and cost.
Which robot platform makes the most sense?
As a rule of thumb, compared to a Cartesian robot, a SCARA or six-axis system will deliver higher performance out of the box at a higher cost and with greater programming requirements, but with a smaller footprint, less weight, and less rigid arm extension. On the other hand, a Cartesian system provides building blocks to create a solution that costs less and involves fewer engineering resources, while proving more rigidity for better precision and higher payloads.
As an example, a six-axis robot can move in all the planes that a human arm does. For applications where there is a mechanical interference, such as a box in a corner with parts inside, a six-axis arm can bend to reach in and grab that part more easily. This type of robot may cost more than a Cartesian solution, but it works for that application.
It's a different case for a pick-and-place application with a 20-kg payload where high accuracy is not required. Both a SCARA and a Cartesian robot could handle the application. But a 20-kg payload is at the upper end of a SCARA robot's capabilities, requiring more costly controls and components. With a Cartesian robot, a 20-kg payload is no problem, which makes it possible to save money by downsizing the mechanics, using smaller components and less complex controls. In this case, a Cartesian choice is a more cost-efficient solution.
Cartesian robots also make sense when the application involves long spans. In one example, a gantry system was constructed from linear modules for an automated storage and retrieval system. The X-axis was nearly 10 m long. A SCARA or six-axis system cannot handle that travel range.
Heavy loads may also be ideal for Cartesian robots. One application example involves a bearing machining center with parts that weigh about 70 kg. These payloads exceed the capabilities for a typical SCARA or six-axis system, unless it's a "Terminator"-size robot. In this case, however, a Cartesian robot was simply bolted to the end of an existing machine to pick and place these parts, eliminating back strain and other safety issues for workers who were manually handling these heavy parts.
An example of a smaller application involves a high-volume medical pipette manufacturer. In this case, space was tight. The manufacturer was able to use compact Cartesian robot modules to achieve the required precision while meeting its space constraints. The company could also use standardized catalog/off-the-shelf components to fit its frame, in addition to motors from the same source and existing controls from a third party -- saving money for a better return on investment.
Advances driving wider robotics adoption
More small-size companies are implementing Cartesian robotics because of these value-adding advancements:
Advances in control technology allow operators to safely enter the machine cage to "teach" the robot coordinates for picking and placing.
Empowering end-users now and in the future
As the cost of implementing robotic systems has decreased significantly in recent years, end-users feel empowered to use robotics in applications far beyond high-volume manufacturing environments. Robotics of all types are being applied in many creative ways, with Cartesian robots being especially notable for "breaking out of their box" due to advances in linear servo motors, modules, standardized components, and operator-friendly controls that lower costs and boost performance. Manufacturers are always striving for faster cycle times to increase throughput and avoid bottlenecks. These advances are providing smaller companies with the productivity gains they need to succeed in a world constantly demanding more flexibility and greater productivity.
Learn more about Bosch Rexroth Linear Modules and Cartesian Systems.
Source: Bosch Rexroth Corp.
Published April 2014