Routing system uses two robots

Routing systems for finishing polymeric and moulded parts can work on larger workpieces and can increase productivity by using two robots.

ABB KMT (formerly ABB I-R) Waterjet Systems has expanded the company's range of robotic routing systems for finishing polymeric and moulded parts with the launch of the new Cutting Box Routing L.

This new routing system offers a larger footprint than the existing Cutting Box S, giving the opportunity to work on larger workpieces and to increase productivity by using two robots in the Box instead of one.

As in the S version, the Cutting Box Routing L ensures high position accuracy for the router with very efficient waste disposal.

The system is easy to install and customise and comes with a global support package second to none, providing technical, service and parts coverage in virtually every country in the world.

Routing is a dry cut process that utilises an electrically powered routing head with a spindle-mounted bit, which is spun at very high speeds up to 50,000 rev/min to trim edges and form holes and slots in a wide range of polymeric materials.

Routing can also be used to cut materials to a pre-defined depth.

The method gives a very accurate material separation and produces a high quality cut edge, with only a light burr that can be easily removed if necessary.

The Cutting Box Routing L utilises the renowned Jaeger range of spindles providing high quality performance for this exacting application.

The design of the fixture is a very critical parameter for the accuracy of the process and ABB KMT always supplies the first fixture with the new Cutting Box Routing L machine, so that the overall absolute tolerance for the machine can be confirmed.

It is essential to avoid quality problems arising from parts becoming loose on the fixture.

The design of the fixture, its stiffness and the contact area between the part and the fixture all contribute to the accuracy of the routing process.

The Cutting Box Routing L utilises a vertical worktable arrangement ensuring excellent ergonomics for loading and unloading parts.

The worktable is two-sided, allowing the operator to load a part, whilst another is being routed on the flipside inside the Box, increasing system productivity.

The part is fixed in place singly or by a combination of clamping and/or vacuum suction.

Sensors mounted on the fixture detect the presence of the part and whether or not it is properly positioned before the routing cycle can begin.

Like the Cutting Box S, the Cutting Box Routing L offers excellent waste disposal, via a conveyor below the vertical worktable, from which debris falls on to the conveyor and is transported out of the box into a waste hopper.

In addition, the airborne dust that always accompanies routing is sucked through ducts either side of the worktable, by a high powered vacuum system that passes the air through filters, before returning the filtered air through floor level vents at the back of the Box.

The flow of filtered air helps to push even more waste material on to the conveyor for removal from the Box.

The new Cutting Box Routing L features up to two IRB 2400/16 M2000 industrial robots from ABB, each offering a 16kg handling capacity and 0.06 mm positional repeatability.

The robots are controlled by the S4Cplus M2000 robot controller.

This utilises the powerful RAPID robot language providing easy human-machine communication, fast signal processing and a modular program structure.

Inside the Box, the 400 lux lighting provides excellent illumination for programming the robot.

The new system offers the highest safety levels and its design exceeds CE Safety Class 4 standards, with a state-of-the-art Failsafe Profibus system which groups all the safety related features in one closed loop.

The Cutting Box Routing L features several interlock switches to prevent any access to the Box whilst routing is taking place.

There are a number of clearly placed emergency stop buttons in case of danger and there is a pre-defined 'Reset' procedure to avoid any accidents in the event of an abnormal stop.

At the front of the Box, there is a light barrier protection system for the turntable loading area with an optional rolling door providing further protection.

The operator panel is on a swivel arm and is located well away from the turntable loading zone.

The Man-Machine interface is excellent with touch sensitive controls on the screen and simple, easy to learn procedures for the user to follow to operate the system.

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