Palletizing robot

Kawasaki Robot

Palletizing robots

ROBOT DIVISION Tokyo Head Office/Robot Division

1-14-5, Kaigan, Minato-ku, Tokyo 105-8315, Japan Phone: +81-3-3435-6852 Fax: +81-3-3437-9880

Akashi Works/Robot Division

1-1, Kawasaki-cho, Akashi, Hyogo 673-8666, Japan Phone: +81-78-921-2946 Fax: +81-78-923-6548

Global Network Kawasaki Robotics (USA), Inc.

28140 Lakeview Drive, Wixom, MI 48393, U.S.A. Phone: +1-248-446-4100 Fax: +1-248-446-4200

Kawasaki Robotics (UK) Ltd.

Unit 4 Easter Court, Europa Boulevard, Westbrook Warrington Cheshire, WA5 7ZB, United Kingdom Phone: +44-1925-71-3000 Fax: +44-1925-71-3001

Kawasaki Robot CAUTIONS TO BE TAKEN TO ENSURE SAFETY l For those persons involved with the operation / service of your system, including Kawasaki Robot, they must strictly observe all safety regulations at all times. They should carefully read the Manuals and other related safety documents.

Kawasaki Robotics Korea, Ltd.

l Products described in this catalogue are general industrial robots. Therefore, if a customer wishes to use the Robot for special purposes, which might endanger operators or if the Robot has any problems, please contact us. We will be pleased to help you.

Kawasaki Robotics (Tianjin) Co., Ltd.

l Be careful as Photographs illustrated in this catalogue are frequently taken after removing safety fences and other safety devices stipulated in the safety regulations from the Robot operation system.

Kawasaki Robotics GmbH

29 Sperberweg, 41468 Neuss, Germany Phone: +49-2131-34260 Fax: +49-2131-3426-22 43, Namdong-daero 215beon-gil, Namdong-gu, Incheon, 21633, Korea Phone: +82-32-821-6941 Fax: +82-32-821-6947 Bldg 3, No.16, Xiang’an Road, TEDA, Tianjin 300457 China Phone: +86-22-5983-1888 Fax: +86-22-5983-1889

Kawasaki Motors Enterprise (Thailand) Co., Ltd.

(Rayong Robot Center) 119/10 Moo 4 T.Pluak Daeng, A.Pluak Daeng, Rayong 21140 Thailand Phone: +66-38-955-040-58 Fax: +66-38-955-145

https://robotics.kawasaki.com/

ISO certified in Akashi Works.

] Materials and specifications are subject to change without notice.

Cat. No. 3L1625 Oct. ’16 S Printed in Japan

Kawasaki’s high-speed palletizing robots meet the demands for flexibility and speed. In today’s highly competitive marketplace, meeting the demand for just-in-time deliveries, flexible packaging, the freshest products, or the highest production line efficiencies can be crucial to a company’s success. Efforts to meet these demands have led to the development of automation systems for the end-of-line and distribution processes of palletizing and depalletizing. Kawasaki’s robotic palletizing solutions provide the pallet pattern flexibility, tooling flexibility, and cycle times needed to deal with multi-variety and small-batch production, and reduce process change costs. Kawasaki Robotics offers three different lines of palletizing robots with a wide range of payload options to suit most needs, including model RD80N with a maximum payload of 80 kg, models ZD130S/250S with maximum payloads of 130/250 kg and models CP180L/300L/500L/700L with maximum payloads of 180/300/500/700 kg. Each has industry leading reach, speed and quality to deliver high-performance automation technology for most any palletizing application. Kawasaki can provide a solution to give your production line the palletizing flexibility and product rate it needs to compete in today's economy. RD080N

CP180L/300L

1

ZD130S/250S

CP500L

CP700L

2

Features Palletizing capacity worthy of our high-speed age Kawasaki palletizing robots deliver the high-speed operation needed for distribution. Based on a robot stroke of 400 mm upward-downward and 2,000 mm in the left-right direction, the RD080N can perform 900 cycles per hour with loads of 80 kg, and the CP180L achieves an industry leading 2,050 cycles per hour with loads of 130 kg.

Compact applications

Palletizing cells Kawasaki provides system configurations perfectly adapted to your needs.

The Kawasaki RD080N is designed specifically for applications where a compact, high-speed, palletizing robot is required. Despite its slim space saving design, the RD80N can manipulate loads up to 80 kg and create pallet stacks over 2 meters tall.

Robot arm Palletizing hand

Safety fence

Workpiece acceptance

Large work envelope and high payload capacity At 3,075 mm and 3,256 mm respectively, the high vertical reach capability of the ZD and CP series robots is ideal for tall pallet stacks and multi-lane applications. The extra-long horizontal reach of 3,255 mm for both series allows for one robot to be used to cover up to four pallets. The high payload capacity CP series robots can handle up to 700 kg. This allows for multiple product picks and complete pallet layer handling, resulting in fewer cycles per completed pallet.

Pallet (outlying) Robot controller

Easy-to-use palletizing software K-SPARC

Carry-in conveyor

Available as an option, Kawasaki’s K-SPARC palletizing software enables users to quickly and easily simulate layout planning and operations, as well as create robot operation programs on a computer.

Space and energy saving The CP series E03 controller is only 25% of the standard palletizing] controller size (41% with transformer unit) and fits under conveyors and other equipment. The E03 controller generates electric power while in a deceleration mode, reducing energy consumption and minimizing CO2 emissions.

Pallet sensors Pallet guide Robot stand

Sample layout for palletizing cells （mm）

Workpieces Workpieces

] in case of E4X

7,850

1,750

Add-on regenerative resistor unit

1,750

Conventional controller

5,800

4,050

6,100

Electricity Regeneration Function

Pallets 800

Pallets

5,000

800

Sample of palletizing cells

System configuration example

Different workpieces sent from the same conveyor are segregated and palletized.

Consume electric power by resistance

E03 Controller

6,500

PC (K-SPARC)

Manipulator (with internal or external valves) Primary air

Integrated electric regeneration unit

Energy Saving

Return electric power to the primary power source 3

USB memory

Control signal

Different workpieces sent from different conveyors are segregated and palletized.

Power

Cell controller

Robot-controller cable

I/O or communication (CC-Link, DeviceNet, etc)

Robot controller

4

Depalletizing cells

Easy-to-use palletizing software You can build an advanced and flexible robot safety system according to the motion condition by monitoring the movements of the robot.

lDetects the 3-D position and posture of stacked bag packages. lA single fixed camera can monitor wide stacking areas. lAble to adjust to changes in peripheral lighting environments and workpiece surface conditions. lNo need for configuring the individual settings of each workpiece stacking pattern. lAble to handle a combination of different types of workpieces at the same time.

lSave Space by limiting the range of robot movements lSafety function can be switched according to the state of safety signal input lIEC61508 (SIL2) and ISO13849-1 (PLd/category 3) certification

LSC (Laser Slit-scan Camera) Range

: 1,600mm

Accuracy : ±10mm

Save space You can reduce the size of the safety fence area by limiting the range of robot movements to the minimum.

1,700 -

Item

3,500mm

Measuring range Objective distance

1,400mm

1,400mm

You can limit the range of robot movements according to the human work area.

1,700mm

Laser class

Class 3R

Dimension

L1,100mm×W125mm×H125mm

Mass

Safety fence area with Cubic-S

Specification L1,400mm×W1,400mm×L1,800mm

Transporting workpieces during robot motion

About 6.5kg

System configuration example Peripheral equipment control panel

DC24V Vision controller

I/O or communication (CC-Link, Device Net, etc)

I/O

Robot controller

Ethernet

Ethernet

Manipulator (with internal or external valves)

LSC (Laser slit-scan camera)

Safety fence without Cubic-S

Robot-controller cable Primary air

Reduced safety fence area

Reduced cycle time

Power Control signal

Item

Other applications ]For these applications, the workpiece sizes and stacking patterns must be configured.

Safety performance

Specification IEC61508 (SIL2) ISO13849-1 (PLd/category3)

Monitoring the number of joints

Maximum 9 joints

Safety function

Motion area monitoring, Joint monitoring, Speed monitoring, Stand still monitoring, Tool orientation monitoring, Protective stop, Emergency stop, Safety status output

Safety input and output

Dual channel safety input 8CH Dual channel safety output 8CH ] It is possible to allocate Safety Status Output Signals and Safety Input Signals of each Safety functions

Depalletizing carton boxes 5

Depalletizing plastic containers 6

Motion range & dimensions

CP180L/300L

210±0.1

320

JT1 180°

380 300

Rear side interference area 170

1,100 Motion range of point "P"

0

JT1 160°

VIEW A

2-ø13H9 ø26

ø0.06 250

Working range based on point P

17

1,550

298

ø94

ø8H7 Dp8

516.2

VIEW A 481.5

1,231.5

481.5

100 100 500

100

8-ø22 ø42

Base installation dimensions

ø22

963

884.6

619.2

100

°

0 11

272.9

45.8

JT3

ø0.04 X

ø0.3 X Y JT3 205°

2,371.2 2,200

Y

750

680

ø80

A

30°

307

1,200

°

Point P

JT2 95 °

450

60

ø50H7 Dp6

X

240

260

165 158

2,062.3 2,079.2

870 1,696.5

A

JT3 JT6±360°

JT2 46°

6-M8 Dp13

277

15°

JT4±360° P JT2 140°

TSM W V S/N D.

Base installation dimensions

JT2 105°

375

474

ø18

JT3 40°

2,526

244

750

255

JT5±10°

500

1,080

30

2,100

150

12-M12 Dp24

ø18

3,255.8

370.8

30°

34.2

R2,9

1,800

340

210±0.1

619.2

JT1 160°

61

400

206

1,100

8-ø18

1,600

R1,1

7 R39

JT1 180°

1,192.7

300 380

RD080N

926.8 3,255

(mm)

(mm)

ZD130S/250S

CP500L 770

5.3

100

98

0

770

ø18

JT1 160°

VIEW A

8-ø22

255

255

Motion range of point "P"

° 50

1,550

250

Working range based on point P

100 450

1,200

3,255.8

2,200

2,200

JT3

100

500

100

8-ø22

0°

11

ø42 30

12

670

A

338.2

481.5

481.5

Base installation dimensions

963

ø22

810

884.6

0°

Point P

JT6±360° JT2 95 °

272.9

JT3

3,075.3

1,250

2,562

A

JT3

750

25

°

JT2 46°

2,371.2

P

240

260

15 300

270

JT4±360°

15°

°

JT2

90

15°

JT3

375

474

Base installation dimensions

750

2,257 1,450

12-M12 Dp24

500

998 300 JT2

300

1,600

1,130.9

R2,9

100

JT1 180°

30°

34.2

160°

30

R1

VIEW A

JT1

1,800

R2,87 1 ,39

8-ø11

125

0

ø15

Rear side interference area

ø0.05

1,600

R1,2 500

0

370

1,800

P

ø18

2-ø25G8

100

125

125

125

100

47

500

300

100

300

75 JT1 180°

R5

1,192.7

926.8

(mm)

7

(mm)

3,255

8

Motion range & dimensions

CP700L

Standard specifications

1,192.7

Rear side interference area

1,600

RD080N

JT1 160°

30°

.2

,34

R29

12-M12 Dp24

R1,2

98

Degrees of freedom (axes)

0

1,800

VIEW A

1,550

250

Working range based on point P 375

A

500

450

Point P

JT4±360° JT2 95 °

100

JT3

JT3

100

3,255.8

2,200

2,371.2

1,200

240

15°

260

474

JT2 46°

Max. speed (°/s)

100

500

100

8-ø22

°

0 11

ø42 30

750

750

255

2562

Max. stroke (°)

Base installation dimensions 884.6

963

5 130

250

Arm rotation

(JT1)

±180

±180

Arm out-in

(JT2)

+140 - –105

+90 - –50

Arm up-down

(JT3)

+40 - –205

+15 - –120

Wrist swivel

(JT4)

±360

±360

Wrist compensation(JT5)

±10

Arm rotation

(JT1)

180

148

95

Arm out-in

(JT2)

180

110

90

Arm up-down

(JT3)

175

130

95

Wrist swivel

(JT4)

360

400

Width

–

]4

190

1,100

1,800

Depth

1,100

1,600

Height

2,062.3

2,200

2

Moment of inertia (kg•m ) Palletizing capacity

]1

13.7

50

100

(cycle/hour)

900

1,700

1,400

(mm)

±0.07

±0.5

540

1,350

Positional repeatability

]2

Mass (kg)

ø22

4

80

Power requirements

272.9

481.5

Working area (mm)

ZD250S

Articulated type

Max. payload (kg)

ø18

JT1 160°

481.5

ZD130S

Arm type

]3

(kVA)

4.5

10

America Controller

E33 E03

Europe

E43

Japan & Asia 926.8

(mm)

3,255

E23

]1: Motion pattern (400 mm up, 2,000 mm horizontal, 400 mm down in a to-and-fro motion) ]2: conforms to ISO9283 ]3: depends on the payload condition and motion patterns ]4: operating angle of the JT5 is ±10 degrees perpendicular to the ground.

CP180L

CP300L

Arm type Degrees of freedom (axes) 180

300

Arm rotation

(JT1)

±160

Arm out-in

(JT2)

+95 - –46

Arm up-down

(JT3)

+15 - –110

Wrist swivel

(JT4)

±360

Wrist compensation(JT5) Max. speed (°/s)

Working area (mm)

CP700L

500

700

4

Max. payload (kg)

Max. stroke (°)

CP500L Articulated type

–

Arm rotation

(JT1)

140

[5

115

[6

85

75

Arm out-in

(JT2)

125

[5

100

[6

80

65

Arm up-down

(JT3)

130

[5

100

[6

80

65

Wrist swivel

(JT4)

400

[5

250

[6

180

170

250

500

1,000

900

Width

1,800

Depth

1,600

Height

2,200 2

Moment of inertia (kg•m ) Palletizing capacity

]1

50

(cycle/hour)

Positional repeatability

]2

100

[5

2,050

1,700r

[5

(mm)

Mass (kg)

[6 [6

±0.5 1,600

Power requirements

]3

(kVA)

1,650 12

America Controller

Europe

E03

Japan & Asia ]1: Motion pattern (400 mm up, 2,000 mm horizontal, 400 mm down in a to-and-fro motion) ]2: conforms to ISO9283 ]3: depends on the payload condition and motion patterns ]5: in case of 130 kg payload and less ]6: in case of 250 kg payload and less

9

10

Controller

E series

Teach pendant

The E Controller combines high performance, unprecedented reliability, a host of integrated features and simple operation, all in a compact design.

Large, color LCD touch screen display. The key arrangement has been optimised through extensive studies of operator hand movements.

]

Features Compact The E03 controller for CP series palletizing robots has far less volume. You can use it in an upright-position or in a stacked installation to reduce the footprint of this controller.

User-friendly operation The easy-to-use teach pendant now incorporates motor power and cycle start at your fingertips. Multiple information screens can be displayed simultaneously. The intuitive teaching interface is simple to use.

Programming ease & flexibility A rich set of programming functions come standard with the E Controller to support a wide range of applications. Functions can be combined and easily configured within a system to suit a particular application. Also, the powerful Kawasaki AS Programming Language provides sophisticated robot motion and sequence controls.

Advanced technologies The enhanced CPU capacity allows for more accurate trajectory control, faster program execution, and quicker loading and saving of files. In addition, memory has been expanded to meet the need for higher program storage capacity. The controller comes equipped with a USB port for external storage devices.

Easy maintenance Modular components with limited cables translate into easy diagnostics and maintenance. A host of maintenance functions are available, including self-diagnostics on hardware and application errors to minimize troubleshooting and reduce MTTR (Mean Time To Repair). Remote diagnostics via the web server function enables service support from anywhere in the world.

Space and energy saving The CP series E03 controller is only 25% of the standard palletizing controller size (41% with transformer unit) and fits under conveyors and other equipment. The E03 controller generates electric power while in a deceleration mode, reducing energy consumption and minimizing CO2 emissions.

E03

E23

Specifications Standard

Standard

E03

E43

Option

America

E33

Europe Japan & Asia Dimensions (mm) Structure Number of controlled axes Drive system Coordinate systems

W550×D580×H278

E23

W630×D550×H950

W730×D550×H1,200

Enclosed structure / Indirect cooling system

Enclosed structure / Indirect cooling system

5

5

Full digital servo system

Full digital servo system

Joint, Base, Tool

Joint, Base, Tool Joint/Linear/Circular Interpolated motion Point to point teaching or language based programming

Operation panel

Cable length

Teach pendant (m) Robot-controller (m)

Mass (kg)

8

8

Motor power off, Hold

Motor power off, Hold

32

32

Max. 96

32

32

Max. 96

E-Stop switch, teach/repeat switch, control power light

E-Stop switch, teach/repeat switch, control power light

5

Teach pendant Auxiliary storage unit Interface

Max. 128

E-Stop switch, teach/ E-Stop switch, teach/repeat repeat/rapid-feed check Rapid-feed check mode switch switch, control power light switch, control power light

5 110

AC200-220V ±10%, 50/60Hz, 3ø

Cycle start switch, motor-on switch, hold/run switch, error light, error reset switch, rapidfeed check mode switch (only on E23) 10, 15 10, 15

195

AC380-415V ±10%, 50/60Hz, 3ø

Transformer unit: 45

AC440-480V ±10%, 60Hz, 3ø

Power requirements Class-D earth connection (Earth connection dedicated to robots), leakage current: Maximum 100mA

Max. 128

5

5 45

AC200-220V ±10%, 50/60Hz, 3ø

Body color

E33: 8 E43: 8 E23: 7

Fixed tool point

Point to point teaching or language based programming

General purpose Input (Channels) signals Output (Channels)

Transformer unit: W580×D580×H178

6

Joint/Linear/Circular Interpolated motion

External operation

E43

E23

Types of motion control

Memory capacity (MB)

E33 E03

Programming

Environmental Ambient temperature (°C) condition Relative humidity (%)

11

Equipped with Enable switches.

]Option

]Transformer unit AC380-415V ±10% or AC440-480V ±10% 50/60Hz, 3ø

]

E33 AC200-220V ±10% AC380-415V ±10% AC515V ±10% AC575V ±10% AC440-480V ±10% 50/60Hz, 3ø

]

Class-D earth connection (Earth connection dedicated to robots), leakage current: Maximum 100mA

0 - 45

0 - 45

35 - 85 (no dew, nor frost allowed)

35 - 85 (no dew, nor frost allowed)

Munsell 10GY9/1 equivalent

Munsell 10GY9/1 equivalent

TFT color LCD display with touch-panel, E-Stop switch, teach lock switch, Enable switch

TFT color LCD display with touch-panel, E-Stop switch, teach lock switch, Enable switch

–

–

USB, Ethernet (100BASE-TX), RS-232C

USB, Ethernet (100BASE-TX), RS-232C

USB Memory

12

External view & dimensions

(mm)

E03

(mm)

E23

550 550 550 550

Transformer unit ]

580 580 580 580

450 450 450 450

This software lets you configure the pick and place positions of the workpieces by robots and register workpieces, pallets, and stacking patterns displayed on your computer’s screen. It also allows you to easily create robot operation programs .

180 180 180 180

This optional software is one of the application programs built on K-ROSET, Kawasaki’s offline teaching software. 950 950 950 950

550 550 550 550

1818 260 260 18 18 260 260

580 580 580 580

1818 170 170 18 18 170 170

550 550 550 550

Simple palletizing software (option)

Easy setup by layout selection

K-ROSET functions can be used

Support for up to two pick positions and four place positions of workpieces by robots. Simply select a layout and enter a distance!

With K-ROSET, users can specify the layout by analyzing the installation positions automatically according to the robot types and place positions. You can also check for interference and perform cycle time analysis.

Easy registration of item types

Support for many kinds of stacking patterns

]Option

(mm)

1,200 1,200 1,200 1,200

550 550 550 550

550 550 550 550

(mm)

E33

180 180 180 180

550 550 550 550

550 550 550 550

180 180 180 180

1,200 1,200 1,200 1,200

E43

Item types are registered simply by entering data on your computer for workpieces, pallets, and stacking patterns.

13

Approximately 100 types of base patterns can be configured for each stage. The place position of workpieces can be specified. Gaps can also be adjusted.

14