A higher-level control system or complex programming is not necessary. The result is a system consisting of seven axes that is ready for operation within a very short time and is highly tolerant of changes in speed.

Making processes leaner, optimizing workflows - this goal of lean production can be achieved by synchronizing processes, among other things. One example of this is the "flying saw". The principle comes from the woodworking industry and describes the processing of material during transportation. Tree trunks are cut to size while they are being transported. The saw moves synchronously with the conveyor belt. However, the synchronization of processes not only enables tree trunks to be cut, but also numerous industrial applications. Whether it is pick-and-place processes, sorting, separating and checking material or aligning components - synchronization leads to accelerated work processes and therefore shorter process times.

The right components for every application

Synchronized processes optimize the flow of goods. With Item, these can be realized without great effort. For this purpose, aluminum profiles from the Item modular system are combined with linear and conveyor technology as well as robot technology. High-resolution signal processing enables synchronization without complex controls. All components can be connected to each other simply and easily thanks to the system groove and corresponding connection technology. Conveyor belts are available that vary in length, width, speed and surface quality of the belts and can therefore be adapted to different requirements.

Item's portfolio also includes numerous linear units that can be selected to suit the intended use. They can be individually configured and can move robots of different designs. The linear technology meets different requirements in terms of speed, payload, accuracy and stroke length. Item also uses a rotary encoder and a light barrier as additional components to enable the synchronization of two independent processes.

The principle of the "flying saw" simply implemented

For the Range Extender application example, item has installed a Cobot on a linear unit that moves parallel to a 6-metre-long conveyor belt. The substructure of the entire system consists of aluminum profiles from the item Building Kit System. Following the principle of the "flying saw", a workpiece carrier is located on the conveyor belt, which is processed during transportation on the conveyor belt. The Cobot grabs components from the belt and changes their sequence.

At the start of the process, the workpiece moves through an installed light barrier. This triggers the start of the rest of the process. The trigger signal is transmitted to the control system. As soon as the synchronous position is reached, the robot controller receives the command to start work. A rotary encoder transmits the speed of the conveyor belt to the control system at all times. This ensures that the movement of the conveyor belt and linear unit is always synchronized. As the rotary encoder is continuously evaluated by the control system, the target and actual values are constantly compared. If the speed of the conveyor belt changes, the speed of the linear unit changes to the same extent. Minor fluctuations are thus compensated for.

The drive and control technology from Item enables the processing task to be completed quickly. The sensor under the conveyor belt detects the speed of the belt with high precision. It is connected to the controller, programming is simple with the Item MotionSoft commissioning software, and the system is immediately ready for operation. "Our control system supports the digital interface. It records the data on the speed of the conveyor belt and passes it on to the linear unit," says Uwe Schmitz, Head of Product Management at Item.

"The linear unit always moves synchronously with the conveyor belt, so that the robot appears to be working in a static position in relation to the workpiece." The system increases the robot's radius of action and creates a dynamic working environment with seven axes. If such a system is designed in the conventional way, numerous individual components and assemblies have to be perfectly coordinated so that they meet the mechanical, electronic and data technology requirements. The planning and design effort is therefore very high and the control system is complex.

Minimize the effort for conception and implementation

With its modular construction kit, Item offers users the opportunity to develop individual solutions based on preconfigured solutions without having to understand every single component in detail. All components fit together and can be connected and expanded as required. This significantly reduces the design effort. As a result, different applications can be realized.

A combination of robot arm and linear unit without conveyor belt is also possible, in which the robot moves to different stations one after the other and performs pre-programmed sequences there. The modular system is not tied to one robot manufacturer, but can be used for all robot types. This provides system manufacturers with numerous options for solving individual tasks in an uncomplicated manner.

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