Projects
Retrofit for high-performance robots
Higher payload, modern safety technology and flexible processes
- Industry
- Metal
- Solution
- Retrofit
AGS implemented a comprehensive retrofit for existing robot cells with new heavy-duty robots, grippers, safety controllers and operator panels. This allows significantly heavier workpieces to be processed, while the control system, communication and safety architecture were brought up to date.
Project highlights
- Heavy-duty robot with 420 kg payload
- New grippers up to 250 kg nominal payload
- Automatic adjustment to different component lengths
- New safety controllers with secure fieldbus communication
- OPC UA connectivity and new HMI panels
- Enhanced safety devices with light curtains and airlocks
- Components from Ø 140–410 mm and up to 2,000 mm in length
Application & machining processes
- Automated infeed and outfeed via conveyor technology
- Component recognition via sensors
- Servo-controlled gripping of heavy bottle bodies
- Handling in multiple work areas such as blasting, hanging, cleaning and packaging
- Expandability through additional gripper and tunnel systems
Operating & control concept
- Safety PLC for the robot cells
- Touch panels for operation and diagnostics
- Secure communication between system areas
- OPC UA interface for higher-level systems
Safety concept
- Light grids, airlocks and safety-monitored doors
- Safety control system for all cells
- Additional protective measures for heavy-duty robotics
- Access and release logic for operation and maintenance
Result
- Higher payload and expanded workpiece spectrum
- Updated safety architecture
- Improved process quality and usability
- Modularly expandable existing cells
Insights | Process
Conclusion
The retrofit upgraded existing robot cells for higher loads, modern communication, and current safety requirements.