Market trends and business prospects

Commentary by David Edwards on November 2, 2021

ABB has launched a series of new modular machine management application units for the metal industry, designed to maximize flexibility and machine utilization, while minimizing the loss of productivity due to unexpected shutdowns.

The FlexLoader M series is available in six different versions, providing multiple ways of loading and unloading machines according to the size, shape and quantity of the workpieces to be processed, making it an ideal choice for applications such as casting and die-casting operations that produce multiple types of products.

Andrea Cassoni, General Manager of ABB Robotics' General Industrial Business Line, said: “As customers demand more variety and shorter delivery times, metal producers need a manufacturing process that can respond quickly and provide flexibility to achieve high-mix, low-volume manufacturing. And mass production.

"FlexLoader M accelerates this process by providing a unified machine tool management platform that provides the flexibility needed to handle a variety of production needs, while also increasing productivity by eliminating the time, costs and interruptions traditionally associated with production changes ."

The release started with Tray and Conveyor variants, and more variants will be released in the next few months. FlexLoader M Conveyor uses a simple but powerful vision system that can easily load workpieces with complex shapes and provides the flexibility of using a single unit to process various workpieces.

FlexLoader M Tray is a drawer type solution for easy management of the machine. It has a small footprint and can be placed almost anywhere. It is very suitable for processing all kinds of workpieces with different shapes, such as cubes, cylinders, plates and tubes.

FlexLoader M has standardized interchangeable modules and provides flexible and scalable solutions for various machine management applications including lathes, milling machines, CNCs and machining centers. A key benefit is the ability to use the same basic machine and swap in and out feed modules as demand changes.

The modular approach of FlexLoader M makes it easy to upgrade and expand. On average, installation and commissioning only take one to two days.

FlexLoader M meets manufacturers' needs for simple automation solutions that can produce more parts in a shorter time. According to ABB, even without specific robotics expertise, the FlexLoader M robot cell is "very user-friendly and quickly programmable."

The intelligent wizard allows new parts to be programmed in 5 minutes, without the need for visual programming expertise, and the conversion between programmed parts can be completed in less than one minute, making "batch size" production a reality.

The simplicity of the programming software means that complete operator training can be completed in less than half a day, further reducing the time required to put the unit into operation.

FlexLoader M can reduce the labor cost of the machine management process by up to 90%, and an operator can handle up to 10 units at the same time. The machine utilization rate of automated systems exceeds 97%, while the utilization rate of manually operated machines is 40-60%.

All models can be equipped with a vision system that can identify the position of the workpiece and issue instructions to robots, machine tools, and other unit equipment (such as air purification stations, part marking, deburring and measurement systems). Depending on the application, the vision system can use a 2D camera or a 3D sensor.

FlexLoader M also integrates data-based optimization functions, including remote monitoring, enabling operators to monitor, troubleshoot and optimize their robotic systems, while its vision software provides additional functions including status monitoring, fleet management, and performance and order management.

FlexLoader M will replace ABB's existing FlexLoader unit series, which has a reputation for providing reliable and predictable output.

The benefits of FlexLoader units include higher machine utilization and the opportunity for light-off production through unmanned operation. They have proven to provide a faster return on investment while providing users with a sustainable competitive advantage.

Submitted as follows: industrial robot, news tagged as: abb, unit, flexibility, flexloader, including, machine, production, system, tending, variety, vision, workpiece

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