From bulk parts to completed euro-pallets through mounting, packing, packaging with bar code in 4 different product types: those are the necessary steps to produce and ship plastic sockets for fire alarm.The operator simply brings the goods to the line and takes out the pallet.Can such a complex application be automated?

Swiss companies must differentiate themselves from the crowd

There are not that many arguments pleading for Switzerland as centre of production. Nonetheless, there are very successful companies in that country that are able to gain customers back from Chinese production.Wild & Küpfer AG is a good example of this: this dynamic and healthy family-owned company is working in the plastic industry. The answer to worldwide competition is: yes, such a complex application as described above can and needs automation. The results are extremely satisfactory.

New technologies such as intelligent robots offer new possibilities

The current state of the robot technology is impressive. Robots are more than moving objects. Features such as collision detection, logical tasks, palletizing, communication with peripherals through Ethernet, HMI functions, multi-tasking, remote diagnostics… are nowadays standards.At Wild & Küpfer AG, 3 communicating robots can work 5 hours in a row without operator intervention with an impressive cycle time of 6 seconds per fire alarm to perform following tasks:

- Recognition of every socket housing
- Part location
- Laser labeling
- Clamp isolating and mounting
- Checking the spring clamp color, part mounting
- Preparing the instruction leaflet
- Product stacking and packing in bag
- Bag labeling
- Finished bags palletizing

Vision system replaces fragile mechanic

Vision systems are getting financially more and more interesting and are offering new functions. In this installation, 2 systems are in use:

- The first one recognizes the socket housing and gives its exact position (coordinates and orientation) to the robot
- The second one checks the color of the spring clamp and whether it is correctly in the plastic bag.

Modular programming – constant flexibility

For system integrators like Robotec, using robots offer very high flexibility, thus increasing the standardization of every separate cell.It also save floor space and enables to change only part of the installation when needed.

Complete FANUC solution – synergies in the FANUC world

Robotec is Authorized System Integrator for FANUC robots but is also using GE Fanuc CNC. This ensures smooth interface for fieldbus, visualization and Ethernet protocols.For example, an additional axis for a robot consists in the same components as a CNC axis, and can be integrated within minutes.Such advantages are very clear with visualization functions: at Wild&Küpfer, a GE Fanuc QuickPanel™ was installed, running with Windows CE on a SoftCNC. This ensures highest time saving compared to other technologies such as VPN.This also helps very quick operating for the most important functions: start, stop, problem solving, product change, all this can be managed in pressing a few keys. Issues such as robot collision or blocked parts are directly managed by the CNC.