Robocoating Self-Teach Paint Robots

As one of the most effective ways to solve today's painting problems, Robocoating painting robots can be shown, thanks to their easy teaching method. Thanks to this system, the painting operator performs manual painting together with the robot. If the painting quality is suitable, the robot repeats all of the operator's applications, allowing you to switch to standard production.

System content

• LeBot LC R 500 5-axis R 500 model, • LeCRob ECO Robot Controller, • Matching: Encoder for Speed Control.

Option

• Manufacturing and Program Sequence Management, • Access control system to the operation area according to CE standards, • Protective kit.

5-Axis R500 Robot

Features

The robot arms are manufactured from aluminum to provide ease of operation during the programming stage, and are balanced with pneumatic cylinders to minimize carrying tension. The robot's wrist structure is designed to allow the wrist to move in every direction, independent of the inclination of the arms, enabling the painting of hard-to-reach surfaces. Manufactured as explosion-proof/non-combustible in accordance with the Atex Specification, the 5-axis robot LeCRob ECO is equipped with a state-of-the-art electric-driven control unit. The use of the robot is simple and practical. The most important stage in commissioning is the learning/teaching and application of programs. Programming of the robot is carried out in 3 stages. • Program setup: Begins with the new program number being added to the current program list.

• Running the teach mode:

Manually teaching the painting movement to the robot is quite easy due to the lightness of the robot arm and its ease of movement. During this process, while the taught movements are being stored in memory, OK signals are also sent to the spray gun. Different modules that follow one another can be applied in a program. • Merging of programs: In the program, consecutive modules can be listed according to the order of operation. All operations at this stage are quite simple, and an operator who has received one or two hours of training can operate the system with ease. During programming, it is possible to control functions such as rotation groups, the carrying fixture, gun parameters, etc. for polishing optimization. When the robot is used together with a conveyor on the production line, the robot speed can be coupled to the line speed thanks to the SNYCRO system. In teach mode, the line speed is loaded into (introduced to) the program. When the program is run, depending on whether the line speed is slow or fast, the robot will adapt its operating speed to the actual speed of the conveyor system.

LeCRob ECO: Paint Robot Control Mechanism

Lesta, which has years of professional experience in the automatic painting sector, carries out the production and sale of the newly developed LeCRob/LeCRob ECO Paint robots. The control mechanism, equipped with innovative technical features, makes LeCRob Robot solutions compatible with both new and retrofitted machines. The operation of the robot is carried out with the LeCRob Robot Manager software, which will be explained in detail in the following lines. The robot applications of various types and sizes that we have carried out in various sectors to date enable us to guarantee, with great confidence, the quality and efficiency of the committed solution.

The details of the proposed system are as follows:

• The robot's operating and planning system with 15" touch-screen monitor compatible with Windows XP; thanks to the Internet connection of the PC in use, remote connection to our emergency help and support line is possible to solve the problem. • Teach keys with suitable configuration, • External unit for program storage and management, • Coupling of line speed with external encoders, • 24 VDC 16 digital inputs, 16 digital outputs. 2 digital output relays (alarm and current cycle), 8 program entries are possible in teach mode and are automatically repeated. • Expandable digital and analog inputs and outputs compatible with customer requests • Absolute encoder, • Analog-controlled DC drive, • DC motor with maximum speed of 4000 rpm, • 3x400Vac Power.

Software Control Content

In addition to the standard features of teachable paint robots, the LeCRob Robot Manager software contains many innovations. During painting, the speed of the robot can be adjusted automatically. The robot speed can be increased from 30% to 150%, provided it remains within the permitted maximum limits. When the system intersects with the line speed reader, the software automatically becomes compatible with the robot speed. When the product changes, it adapts to the speed of the new line without waiting. It allows programs to be modified in accordance with the control parameters (atomization, flow, fan) of the spray guns. It has the feature of loading programs externally via USB flash memory or within a network, eliminating limits. It has the features of instant program loading and management of programs with 32-character alphanumeric codes. Each program has a linked image and/or notes in the form of a PDF file. In the management of stops during painting, when the robot is stopped for any reason during the painting process and restarted, unexpected movements are prevented and continuity of synchronization is ensured. Easy and fast encoder verification is performed, along with intuitive calibration via the encoder wizard feature. With the 5-level password management feature, it is ensured that the robot can only be used by authorized personnel. If the part performs rotational movements during painting, without disrupting the workflow, it has the ability to adapt to each stage and speed of rotation, taking into account the physical properties of the painted parts.

Software optimization can be done via the touch screen

• Automatically cleaned spray gun, • Intuitive alarm feature that facilitates diagnosis, • Storage of production data, • Enabling automatic color change, • Ability to prepare point-to-point programs, • Maximum expandability for additional new features, • Ability to remotely and instantly intervene in any kind of problem with a fast internet connection, • Multilingual interface allows text and messages to be translated with the help of a simple excel table.

Additional options

• Monitoring of the factory or warehouse, or taking photographs of painted parts, thanks to IP camera connection, • Ability to communicate via Skype channel integrated with the user interface, • Thanks to LeCRob's new control unit, previously taught programs can be converted and adapted, • Daily production can be tracked from any location with an internet connection thanks to the LeCRob Manufacturing Manager software; this software allows daily work orders to be programmed. • Ability to be compatible/intersect with a paint control unit supplied by third parties, • The robot's operating system and software have been developed by Lesta Srl. Customer-specific applications and modifications can also be easily made after installation. • Operator interfaces are easy to use and touch-screen based.

Innovative Perspective

The LeCRob Robot Manager software and all other optional software have been prepared according to the principle of simplicity and ease, in a way that can be used in many countries. Our software development team provides products and services that are compatible with the customer's requests. More generally, we would like to draw your attention to the following points as well. The robot's control software is provided either on the robot itself or via remote connection. Multiple PCs can be connected to the same robot. The remote connection feature allows us to examine the robot on-site; issues such as software control, fault detection, inspection of additional features, and expansion of the working area can be addressed. Data regarding production planning and work orders can be recalled and analyzed. By placing touch-screen panels anywhere in the production area, the operation and performance of the robot can be monitored. Option: Management of production and sequencing of programs.

Specifications:

Control of the production flow and the sequence of programs is controlled by a PC placed near the loading point of the parts on the conveyor line. The operator who loads the parts onto the conveyor enters the code into the system with each model change. This process leads us to two results: • Automatically recalling the technical information loaded into the robot and, as a result, informing the operator which processes are to be applied to the part (e.g. masking, etc.). • Placing the newly loaded part into the queue. Thanks to this system, the sequencing of all parts within the system flow can be tracked, and the operator can make program or color changes here. There must be a PC with software installed at the loading area. Queue Management "Basic", PC (OS Windows 7), 15" touch screen.

LeCRob Production Management Software

• Production Management program for different processes to be applied to parts, • AS 400-compatible reporting and production module to be supplied by the customer, • Interface for signal transmission and flow, • Protective cabinet for the PC.

Selim Şahin Genel Müdür / General Manager Robocoating Türkiye Robotik Boya Makinaları Endüstriyel Tesisler ve Malzemeleri San. Tic. Ltd. Şti.