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Robotic Applications In Wood Ind

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					Robotic Applications In Wood Industries
                                Dates : Jan. 12 & 13, 2010
                                        10.10a.m 11 25a m
                                Time : 10 10a m - 11.25a.m
                                Venue : INTROP 3, UPM
                                Presented by :
                                Robert Chen - Regional Manager
                                KUKA Robot Automation (M) Sdn. Bhd.




                 www.kuka.com
KUKA Robot Group – Technology Leader in General Industries
      Aerospace                                   Beverage         Chemicals & Plastic    Electronic & Electrical     Entertainment




     Food & Meat                                Glass, ceramic &   Logistic / Warehouse
                                                                                               Medical               Metalworking
      Processing                                 Mineral product    Handling products




Rapid Prototyping,                                                   Pharmaceutical
Milling & Deburring                                  Mining            Products            Testing & Inspection     Wood & Furniture




KUKA Robot Group | Jan 12 & 13, 2010 | Page 2                           www.kuka.com
  Contents Of Presentation :

1. Wood              & Furniture Industries
           Structure Overview - Wood & Furniture Industries

2
2. KUKA Robotic Applications In Wood Sector
           Robotic Handling Applications ( Movies )
           Robotic Assembling Applications ( Movies )
           Robotic Machining Applications ( Movies )

3. The Rationale Of Robot Usage In Wood Sector
           What Are Those Benefits Gained From Robot Deployment ?
           Various Concerns : Logistics, Quality, Working Condition, Manufacturing Costs

4. How KUKA Robotic solutions are realized ?
5. Brief         Intro. - KUKA Unique CAMROB Technology Package
6. Information Sharing / Discussion

   KUKA Robot Group | Jan 12 & 13, 2010 | Page 3   www.kuka.com
1. Structure - Wood & Furniture Industries


        Wood & Furniture Industries                                              Small Trade
                                                                                            SMEs
                                                                                              General
Furniture Industry                                Wood Industry                               Assembling
Kitchen product
Living, trendy / stylish
Li i    t   d     t li h
product                      Building &                        Derived           Sawing & Milling
Upholsteries                Construction                   Timber Products
Office furniture         Frame construction                    p
                                                            Chip board                 p
                                                                                  Raw product
Bedroom product          Engineered woods                   OSB- board / Wafer    Semi-finished product
                         construction                       board                 Finished product
                         Timber panels                      MDF- board            Lumber
                          construction                      Composite             Milled timber product
                         Mineral composite                  Wood plastic          Fuel – Alternative Energy
                                                            composite ( WPC )            Wood burned to produce
                                                                                         heat or power
                                                            Paper & pulp


 KUKA Robot Group | Jan 12 & 13, 2010 | Page 4   www.kuka.com
2. KUKA Robotic Solutions In Wood Sector




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 5   www.kuka.com
Three Main Applications Of Robot Deployment



                                                 ~ 10 %
                                                                   ~5%



              Handling

~ 85 %                                           Assembling
                                                                 Machining

 KUKA Robot Group | Jan 12 & 13, 2010 | Page 6    www.kuka.com
 Robotic Handling Applications

                                                   Material Handling and Transportation are essential elements in
                                                   logistics of a company. Robots are used in logistics & production
                                                   sectors of different industries especially those areas / processes
                                                                                  labour-
                                                   of highly machine tending or labour-intensive nature.
                                                   Robot provides fast, continuos and secure flow of materials along
                                                                                 value-
                                                   whole production lines with value-added elements in the chain.
                                                   Robot offers higher flexibility as compared to conventional
                                                   kinematics or mechanism ; robot can easily adapt into existing
                                                   system or ready for newer task
                                                   Usually, a robot is possible to undertakes the workload of 3
                                                   workers or more subjected to the applications, the direct benefits
                                                   that a company can gained is the reduced labour cost & wastage,
Robot P f      L di       4- id Planing Machine
R b t Performs Loading At 4-side Pl i   M hi       enhanced machine efficiency, higher system availability and zero
         In Handling Sawn Wood Panels
                                                   or reduced OH&S issues.

KUKA, capable to offer effective robotic solutions to your production difficulties in automation. KUKA has wide
spectrum ranges of robots, tailored for different tasks and industries. KUKA has different identities in the
 p            g            ,
market, a robot manufacturer, a technology leader, a robotic automation system consultant or etc. but KUKA
with worldwide presence carries one common mission, namely to become your growing business partner
For woods industries, parts difference in size, shape & weight are those factors that induce high demands for
                                                                                 KUKA-
universal gripper system and intelligent sensors technologies. In this respect, KUKA-&-Global System Partners
                                                                                               ahead.
or Integrators are capable to render you with the optimum solution against all the challenges ahead



   KUKA Robot Group | Jan 12 & 13, 2010 | Page 7      www.kuka.com
 Palletizing, Pilling, Machines Tending, Machines Unloading / loading, Pick-N-Place, …




Palletizing Of Bark Mulch ( Sack Form )               Robot Pilling Up Bark Briquettes




         g                ,
  Handling Furniture Parts, Pallets &                          g
                                                  World‘s Strongest Robot ( KR1000Titan ) In       p g                    q
                                                                                               Grasping Bundle Of Bark Briquettes
          Separation Sheet                              Handling Stacked MDF Boards



  KUKA Robot Group | Jan 12 & 13, 2010 | Page 8                  www.kuka.com
   Palletizing, Pilling, Machines Tending, Machines Unloading / loading, Pick-N-Place ( Continued )




     At Machine Tending Area                        Pilling Up Panels For Drying Kiln   Handling Parquets ( Flooring Line )




                                 Machines
Handling Parts At 2 Panel Sizing Machines Handling Parts At 1 Panel Sizing Machine                       Knocked-
                                                                                                Handling Knocked-down Furniture Parts




    KUKA Robot Group | Jan 12 & 13, 2010 | Page 9                      www.kuka.com
Robotic Assembling Applications

                                                                    furnituresindustries,
                                                   In woods and furnituresindustries, you can discover lots of
                                                   different yet arduous assembling tasks which often similar in
                                                                                           repeatability.
                                                   process step and with have high rate of repeatability. It is crucial
                                                   to automates these processes because majority of them are not
                                                       value-      task.
                                                   the value-added task.
                                                   In general, a customised design of assembling mechanism or
                                                   system is limited for a known task in manufacturing one product
                                                   or sometimes if possible, also can cater for certain range of
                                                                                             homogenous.
                                                   products which are similar in shape or homogenous. This kind of
                                                   solution is not feasible to automate various assembling tasks with
                                                   high system flexibility yet investment proof for future products that
                                                                                    task(s).
                                                   requires additional processing task(s).
                                                   The above system shortcoming is possible to be eliminated by
          KUKA Innovative Solution
        Semi-Auto Robotic Sysytem
        Semi-                                      KUKA‘s unique technology package ( subject to application ) and
  In Assembling Backrests Of Office Chairs                                                  multi-
                                                   the optional Tool Changer, which enables multi-tasking function
( Where the new technology story begins ... )                                 task.
                                                   for various tasks or newer task.
                                                                           Force-
                                                   The usage of KUKA Force-Torque Control ( FTCtrl ) technology
                                                   package enables the Robot to control and constantly monitoring
                                                   the force and torque exerted on part which will affect or determine
                                                                                                process.
                                                   the final quality and the reliability of the process. Robot‘s extended
                                                   functionality like measuring, testing and inspection can be
                                                                                                     system.
                                                   accomplished by sensors and 2D or 3D vision system.



  KUKA Robot Group | Jan 12 & 13, 2010 | Page 10         www.kuka.com
Drilling, Screwing, Clamping, Plugging, Gluing, Cutting, Bending, Fitting, …




  Cutting With Sonic Knife
                                                  Gluing          Surface Gluing      Drawers Assembling 1       Fixing Of Boards
                                                                   Application        Drawers Assembling 2     With Clamping Device




 Tool Changing System




                                                  Drilling            Glazing Of Kitchen Cabinets            Making Pallets



 KUKA Robot Group | Jan 12 & 13, 2010 | Page 11              www.kuka.com
   Machining

                                                                                                      (O.
                                                      In terms of Overall Equipment Effectiveness (O.E.E) and Return Of
                                                      Investment (ROI) viewpoint, an effective and economical automatic
                                                      production system yet uncompromising with consistency in
                                                      improved quality and enhanced productivity is at high demand. demand.
                                                      Wood process automation requirements has become even more
                                                                                                                     market.
                                                      stringent in order to regain product’s competitive edge in the market.
                                                      The robot‘s rigidity and repeatability have greatly improved with
                                                                                        available.
                                                      nowadays advanced technologies available. Thus, allowing a 6-axis
                                                      articulated robot to be deployed for machining tasks for primary &
                                                      also secondary process, possible working on soft materials basis
                                                      (Wood, plastics, aluminum, composite material, even stone and etc)
                                               In the woods and furniture industries, you can find unique scope
 KUKA Milling Robot Traversing On The External where robot can be used in more reasonable & economical way. In  way.
          Linear Track ( The 7th. Axis )       this respect, the robot offers buyer with its high flexibility, mobility
                                               and wide selection of robots range that can fit into most of the
                                                                                 one.
                                               requirements even the stringent one.
Another big advantage of using robot is the possible combination of handling and machining tasks in one single
                                                                                      work-
system, independent from the older fact that the robot can only either moves the work-piece or the tool or both. both.
The robot‘s functionality can be extended by either KUKA unique technology package or integrates with other
                                                                                                        problems.
specialty item or combination of both as a total robotic solution in solving any production automation problems.
The robot‘s working envelope can be enlarged by using an additional linear track ( either floor or ceiling mounted ),
               th.                                 30m                                                          robot.
serves as the 7th. axis ( extension possible up to 30m or more ) that fully synchronized with all 6 axes of the robot.


     KUKA Robot Group | Jan 12 & 13, 2010 | Page 12         www.kuka.com
Prototyping, Modeling, Grinding, Sanding, Polishing, Deburring, Milling, Sawing, …


                                                                                     Contour Milling Of A
                                                                                      Chair‘s Backrest




                                                                                                            Cutting & Trimming Of
                                                                                                              Chair‘s Backrest
    Milling In Big Part ( Foam )
                                                         Surface Brushing
                                                         & Dust Exhausting




                                                                Mill Hole & Slot
                                                                                        Rapid Prototyping
    Sanding Of
    Chair‘s Seat
                                                                                                               Polishing Chair‘s
                                                                                                            Supporting base ( Feet )

                                            Milling Openings



 KUKA Robot Group | Jan 12 & 13, 2010 | Page 13                       www.kuka.com
3. The Rationale Of Robot Usage In Wood Sector




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 14   www.kuka.com
 What Are Those Benefits Gained From Robot Deployment ?
 ( Summary )
4 Main Reasons – Why A Company Needs Robotic Automation ?
LOGISTICS
•  System Layout       Neat    facilitates effective production planning & maintenance
•  Just-in-
   Just-in-time (JIT) Mfg. / Prod.     Possible implementation
                Focusing on                                 over-
                                 Reduced Inventory / No over-stock / Minimized wastage
•  Product Cycle time      is known or predictable
•  Production changes ( model or batch )         Offer high flexibility & adaptability
       QUALITY
•  Reject ratio ( due to human error )      Minimized     wastage, disposal cost reduced
•  Good parts Qty      Increased         re-
                                      No re-work time loss ( labour + material costs )
•  Throughput      Consistent      Reliable     Production Qty Up
•           up-
   System up-time                                                down-
                        High availability with zero or minimal down-time
                 PEOPLE
•  Smart use of “ Human Capital “ Higher level job            Planning + Management
                          TOTAL COST OF PRODUCTION
•  Overall Equipment Effectiveness ( OEE )                           value-
                                                   Enhanced, with value-added process
•  Company‘s return       Faster & Higher      Payback ( ROI ) time       shortened
•  Mfg.     t i
   Mf cost / piece      Reduced
                        R d     d     C         ‘         titi    d i        k t i d
                                      Company‘s competitive edge in market gained !


  KUKA Robot Group | Jan 12 & 13, 2010 | Page 15   www.kuka.com
 Logistics Aspect

  Flexible Process, Production & Layout Design
      p                    y
1. Simplified Production Layout
        Space-
        Space-saving, footprint gained - cater for other usage
        Offer high degree of freedom & mobility in terms of
                             prod.
        future relocation or prod layout changes / expansion
2. Higher Flexibility
         Easily adapt to production changes with minimal
                     change-
         production change-over time ( solely involves Robot program
                     pre-
         selection & pre-run only ) with physically no / min. mechanical adjustment
                                                       system
          For new product introduction into existing system, as long as the
          product(s) fall within the capability of robot & its gripper, no mechanical
          design changes is necessary except those peripheries ( conveyors
             t        t    hi h        bj t d t      t l       i      t l
          system & etc ) which are subjected to actual requirement only.

  KUKA Robot Group | Jan 12 & 13, 2010 | Page 16   www.kuka.com
 Logistics Aspect

  Flexible Process, Production & Layout Design
3. Less Steel Parts         no more bulky construction with reduction of intricate
                         gantry             requires
     kinematics ( linear gantr & etc ) that req ires high maintenance costs
4. Neat Layout With Factory Automation
                          y        g      p
         Facilitates Safety Planning for Operator / Production / Whole Plant
         Not prone to Occupational Health & Safety ( OH&S ) unwanted issue
5. Product Cycle Time              Is known ( predictable ) with robotic automation
          Thus Facilitates effective production planning
          Thus,                                              No production shortfall
           owing to human errors      Company‘s business is secured
                                       Just-In-
          Possible implementation of Just-In-Time ( JIT ) Mfg. & Prod. concept
          Focusing on     Reduced Inventory          over-
                                                 No over-stock / Minimized wastage
6. Possible Combination              Manual & Automatic operation.
            Robot-
            Robot-Human Interaction via KUKA safe robot technology


  KUKA Robot Group | Jan 12 & 13, 2010 | Page 17   www.kuka.com
     Quality Aspect

     Quality Assurance
1. Consistency in quality regardless of batch size.
2. High repeatability of the same quality part
3. Consistent, Continual High production output
4.               Up-                                  non-
   High System Up-time, thus High availability with non-stop production
5. No business to be jeopardized by possible shortfall of production quantities,
   delay in delivery time because of high rejection of parts due to human error.
6.          beings,
6 Human beings easily prone to mistake & emotional acts if they are under
   uncomfortable working conditions ( ex. : hotness, wetness, dusty, smelly &
   etc. ) & high working pressure to meet dateline ( includes working overtime ).
   Individual‘s behavior / habit & daily constitutions ( family, financial & work
   Individual s
   rapport at working place ) might contribute to such happening if the aforesaid
   constitutions are not healthy BUT a Robot will not pose this problem.
7. Zero or minimal reject ratio only if using robotic system


     KUKA Robot Group | Jan 12 & 13, 2010 | Page 18   www.kuka.com
  Working Conditions / Heathly Workplace Aspect

  Improved Working Condition(s) For Human Beings
1. Reduction of operator‘s physical stress, backache & illness due to unhealthy
            environment,
   working environment thus increase overall production performance
2. Say “ NO !!! “ to monotonous & repetitive work – same work routine for
                            pre-              robot.
   operator to work like a pre-programmed robot. Less opportunity for personal
   development or constructive career advancement ( seldom or basically no
   evaluation criteria(s) can be set for the same task )




           X
  KUKA Robot Group | Jan 12 & 13, 2010 | Page 19   www.kuka.com
  Working Conditions / Heathly Workplace Aspect

  Improved Working Condition(s) For Human Beings
4. Higher degree of work safety with robot deployment, can bring accident rate
   due to operator carelessness to minimum or zero
                                                      (brain-
5. Transferring human beings to high value activities (brain-worker) as follows
                                                 labour-
          To transform those arduous ( extremely labour-intensive, time consuming ) & repetitive
                      into li k high     f               ti     i     b ti
           processes i t slick & hi h performance operations using robotics
           Generates More Time – For R&D or Improvement on existing / new process or product
                                   ( innovation )   Regain / sharpen company‘s competitive edge
            For Production system improvement - Feasibility study on possible modification,
                                           value-
            integration or introduction of value-added process ( increase productivity )
            For Effective Management ( Factory operation, production planning, SCM & etc )
6. Create highly motivated, pleasant & healthy working environment for workers
   to work effectively, act more rationally & willing to contribute ideas to improve
   further (brainstorming). More constructive interaction takes place amongst
   teams rather than highly/totally isolated
   t        th th hi hl /t t ll i l t d         i di
                                                indirectly reduce job hopping.
                                                        tl   d     j bh     i

   KUKA Robot Group | Jan 12 & 13, 2010 | Page 20   www.kuka.com
Working Conditions / Healthy Work-place Aspect




KUKA Robot Group | Jan 12 & 13, 2010 | Page 21   www.kuka.com
Manufacturing Cost Aspect

Reduction In Manufacturing Cost
1. Cost Reduction
      Labour expenses for rotating shifts
      Some system is possible with unattended or unmanned operation
                                    p                        p
   ( needs no or lesser number of operators with minimal supervision )
      via Robot, can run 24 Hours x 7 Days.
   No tea break, no holiday, no complaint, no O.T claim, no emotional act
   under harsh working environment ( hot, dusty, smelly, noisy, lighting & etc )
                       g               hot,     y      y       y g     g
3. Minimizing     Reject Ratio ( human error )   Reduced Material wastage
4. Maximizing     Improved quality part    Increased Production output
5 Less Expenses in
5.
      Operator‘s safety protection devices & study methods in working
   environmental design
      Can use standard equipment with no special engineering required

KUKA Robot Group | Jan 12 & 13, 2010 | Page 22   www.kuka.com
Manufacturing Cost Aspect ( continued )

Reduction In Manufacturing Cost
6. Minimizing
                           Down-
     System Setup time, Down-time
     Mfg. cost / piece shorten Payback time / ROI period
     Servicing & Maintenance cost shorten Payback time / ROI period
     Shop-
     Shop-floor‘s footprint requirement ( saved space – can cater for future
   usage or line expansion )
7.
7 Maximizing
              up-
     System up-time ; High system availability, reliability
     Higher throughput & consistency
     Effective plant utilization
     Increase company‘s competitive edges in the market




KUKA Robot Group | Jan 12 & 13, 2010 | Page 23   www.kuka.com
 Manufacturing Cost Aspect ( continued )

 Reduction In Manufacturing Cost
8. Maximizing Company‘s Business Opportunity
       Gain Investor‘s first impression and confidence
       Investors are more willingly to invest or seal contract
       with a company which has applied high level robotic automation
      Security / investment proof – Assurance of product quality and consistency and
                                                      contract-
      also delivery time if mass production basis or contract-manufacturing
         g            p              p y                                y
      Signifies that particular company has achieved certain Quality & Automation
                                                          Safety.
      standard ; Care For System Operation & Workers‘ Safety.
      Having more longer term planning, to cope with more keen & open competitions,
      those emerging threats as follows :
      CEPT Scheme : AFTA trade liberation, non-tariff barriers among ASEAN member
      countries, rising threats from those 3rd. world countries with cheapest labour
      ( ‘Human robot‘ ) costs & also rich in natural resources
                                            Export-             Import-
      China‘s WTO accession – Impact on Export-oriented & Import-Substituting sectors


  KUKA Robot Group | Jan 12 & 13, 2010 | Page 24   www.kuka.com
Brief Intro. - KUKA Unique CAMROB Technology Package




KUKA Robot Group | Jan 12 & 13, 2010 | Page 25   www.kuka.com
                                   5-
 Robotic Milling System Versus CNC 5-axis Machining Center


 KUKA CAMROB Milling System
1. Cheaper & Smaller Footprint Requirement
                      5-
   - As compared to a 5-axis CNC Machining Center
   Larger Working
2. Larger Working Envelope ( Vertically & Horizontally )
                           Z-                     6-
  - Especially in vertical Z-direction ( All KUKA 6-axis articulated Industrial
    Robots have vertical reach easily greater th 2 and max. 5 2
    R b t h          ti l       h    il       t than 2m d           5.2m
    with KUKA’s highest payload robot : variant KR1000L750Titan
3. Capable To Mill Long & Large Part
   - With long reach type robot @ arm extension or external linear track @ mounting types of
     either floor or ceiling mounted
     g              y            y
4. Higher Flexibility & Efficiency
                                                                                            work-
  - Easily integration with other system or even multiple processes in single location / work-
    cell ( part machining, inspection and secondary processes / finishing like deburring,
    polishing & etc ) ; multi robots operation is possible ; robotic loading / unloading of part at
     the front d b k d f the
     th f t end or backend of th process)     )


  KUKA Robot Group | Jan 12 & 13, 2010 | Page 26   www.kuka.com
                                   5-
 Robotic Milling System Versus CNC 5-axis Machining Center


 KUKA CAMROB Milling System
                                  Milling         Medium-
5. Sufficient Robot Stiffness For Milling Soft Or Medium-Soft Materials
              aluminum, wood, foam,                      plastic, fiberglass, stones,
  - Example : aluminum, wood foam thermoformed or molded plastic fiberglass stones
              composites & etc
   Post-
6. Post-Machining, Easy Cleaning Of Chips Or Particles After Milling
     Alt     ti l ith       l
   - Alternatively with enclosed work-cell solution with negative pressure generation
                               d work- ll l ti
                                     k               ith     ti                   ti
     ( dust extraction ) system to prevent dusty problems ( environmental issue )
7. Open Opportunity For Potential Markets As follows,
  -                                                                   rapid-               one-
         Alternative yet akin to CNC machining solution, suitable for rapid-prototyping or one-off
         part milling job or small series of production
  -                        y        +/-                    j     yp
         For Job accuracy around +/-1mm or more ( subject to type of material ( hardness,     ,
         density, nature … ) , actual surface finishing requirements, spindle selection, cutting
         tools, cutting & traverse speed, material removal rate & etc )
  -      R&D, Woodworking, Foundries, Stone, Art, Entertainment & Advertizing Industries,
         Ship ard A tomoti e Aerospace and man more ….
         Shipyard, Automotive,             many


  KUKA Robot Group | Jan 12 & 13, 2010 | Page 27   www.kuka.com
                                  5-
Robotic Milling System Versus CNC 5-axis Machining Center


Examples - Huge Parts Milling I




KUKA Robot Group | Jan 12 & 13, 2010 | Page 28   www.kuka.com
                                  5-
Robotic Milling System Versus CNC 5-axis Machining Center


Examples - Huge Part Milling II




KUKA Robot Group | Jan 12 & 13, 2010 | Page 29   www.kuka.com
                                  5-
Robotic Milling System Versus CNC 5-axis Machining Center


Examples Of - Huge Part Milling III




KUKA Robot Group | Jan 12 & 13, 2010 | Page 30   www.kuka.com
                                  5-
Robotic Milling System Versus CNC 5-axis Machining Center


Examples - Huge Part Milling IV




KUKA Robot Group | Jan 12 & 13, 2010 | Page 31   www.kuka.com
                                  5-
Robotic Milling System Versus CNC 5-axis Machining Center


Examples - Huge Part Milling IV




KUKA Robot Group | Jan 12 & 13, 2010 | Page 32   www.kuka.com
                                   5-
 Robotic Milling System Versus CNC 5-axis Machining Center


    4-        5-     Machining
CNC 4-axis or 5-axis Machining Center
Benefits
   Meant for mass production of the same part
   Can mill steel materials with High accuracy in micron basis
   Better / finer surface finishing
Drawbacks
1. Needs Higher Investment
   Z-            Distance,
2. Z-axis Travel Distance, Normally below 600mm or Limited
 - Conventional CNC machining centers seldom with Z-axis travel greater than 1m as the
  machine is bulky, it requires higher investment and higher ceiling / overhead crane height
3 Larger Footprint Requirement
3. Larger
 - Takes up valuable production floor space that can cater for future usage ; To handle bigger
   part, either will use machine with higher capacity or “ product splitting “ method that will
   pose additional costs, risky for product quality to join-up 2 machined parts as one entity



  KUKA Robot Group | Jan 12 & 13, 2010 | Page 33   www.kuka.com
                                   5-
 Robotic Milling System Versus CNC 5-axis Machining Center


    4-        5-     Machining
CNC 4-axis or 5-axis Machining Center
       Flexibility
4. Low Flexibility
                                                                                        system,
  - Difficult to adapt into existing production line or integrate with other automation system
    majority is of standalone machine
                                                 Part.
5. Longer Product Cycle Time In Processing Large Part.
    Normally h
   -N                 to id         f l
          ll happen t side or awful angle milling, part needs t t k out, overturn or fli 90
                                           l   illi     t   d to takes t       t     flip
   degrees, longer time for re-positioning or adjustment. Machine uptime less.
6. Longer Product Conversion or Changeover ( Production Time Loss )
                CAMROB, the                  f     ffli  i l ti in d to l for
  - With KUKA CAMROB th user can perform offline simulation i order t plan f next   t
    production of newer part without idle time or down-time for current production.
   Post-
7. Post-Machining Cleaning Difficulty
   - For CNC Machine, it is not easy to remove fine particles generated after milling the soft
   material & these particles are harmful to the coolant pump when milling steel materials.
   Not Cost-
8. Not Cost-Effective To Use CNC Machinery For Producing One Single Part
    - Higher costs in producing 3D prototype – product development stage


  KUKA Robot Group | Jan 12 & 13, 2010 | Page 34   www.kuka.com
CAMROB – How It Works ?




KUKA Robot Group | Jan 12 & 13, 2010 | Page 35   www.kuka.com
CAMROB – How It Works ?

                Design                           Contour Simulation with               KUKA Robot
          ( in CAD model )                         collision detection        CAMRob : CNC/NC data Conversion




        Convert CAD                               Tools & Milling process
            to CAM                                   Strategies planning        KUKA Robot Language ( KRL )
       with tooling data                           ( roughing / finishing )




KUKA Robot Group | Jan 12 & 13, 2010 | Page 36                 www.kuka.com
   CAMROB – How It Works ?


                                                     Finished part
                                                     design              Process data


                                                     Material    Design
                                                                 description                       Surface and tolerance
                                                                                  Material         requirements
                                                     Order
                                                     data
                                                                Feature-based
                                                                                    Process                                Volume of material removed
                                                                description of
                                                                                    definition
                                                                delta volume                            Tool
                                                                                                        requirements

                                                                                        Machining
                                                                                                           Tool
The detailed definition of the processing                                               operations
                                                                                                           selection
task within the framework of the NC                                                         Tool t k
                                                                                            T l stock                              Optimization it i
                                                                                                                                   O ti i ti criteria
planning and programming includes
                                                                                                            Machining
activities aimed at defining all required sequences on a                                                    operations
                                                                                                                           Optimization
                                                                                                            with tools                                       Tool-setting
processing machine and the machining operations                                                             assigned
                                                                                                                g                          APT code
                                                                                                                                                             sheet
required to turn an unprocessed part into a finished part.
                                                                                                                                                             CL DATA
                                                                                                                                                NC data
                                                                                                                                                generation
                                                                                                                                                             DIN 66025




    KUKA Robot Group | Jan 12 & 13, 2010 | Page 37                                  www.kuka.com
CAMROB – How It Works ?

          KUKA CAMRob
          - imports 3 different common file types and one proprietary BIN file
                                                                CSV

                    CLDATA
                    ISO3592 (DIN66215)



                                                                NCDATA
                                                                ISO6983 (DIN66025)




KUKA Robot Group | Jan 12 & 13, 2010 | Page 38   www.kuka.com
CAMROB – How It Works ?

                                                                Process Command
                                                                Data Flow & Main Windows




KUKA Robot Group | Jan 12 & 13, 2010 | Page 39   www.kuka.com
CAMROB – How It Works ?

KUKA NC-Verify Program
- To check the compatibility of external code is compatoble with KUKA CAMROB
  - Help File is available, will explain the code that compatible with CAMROB in details




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 40   www.kuka.com
                                   5-
 Robotic Milling System Versus CNC 5-axis Machining Center


3rd. Party - CAD / CAM Softwares
             PCL-
ADEM CAM ( PCL-Germany )                          OPUS                     Woodwork – Holz
BobCAD CAM
BobCAD-CAM                                        PCD800
CADDS5                                            PEPS
                                                                            Orange colour
CAMWorks ( Solidworks )                           Powermill ( Delcam )
                                                                             = Compatible with KUKA
CATIA CAM ( CATIA )                               ProfiCAM
                                                                                 CAMROB
Cimatron E                                        Pro/NC/CAM
                                                                             * Please first approach
Cimatron iT                                       Quadro
                                                                               KUKA local subsidiary
EdgeCAM                                           SolidCAM ( Solidworks )
                                                                               for verification
ESPRIT ( Esprit )                                 SURFCAM
EUKLID                                            Tebis ( TEBIS )
                                                                            Black colour
EXAPT plus                                        TopSolid
                                                                            = not at this moment
FeatureCAM                                        Vector CAD/CAM
                                                                               ( work in progress )
H     MI
HyperMILL ( O     i d
             Openmind )                           Vericut ( Vericut USA )
                                                  V i       V i
JETCAM                                            VISI-Series
MasterCAM ( Mastercam)                            VX
Mold Factory                                      WorkNC ( Sescoi France )


 KUKA Robot Group | Jan 12 & 13, 2010 | Page 41          www.kuka.com
 CAMROB – Potential Markets

Art, Advertisement & Movies Making Industries
Molds and models with high demands in arts, entertainment
                                  industries.
and advertising & movies making industries
  Sculptures
  Statues in commercial art sectors
  Scenery and signage used in Theme parks
  Marketing Samples such as giant tooth brush,
  Models for the advertising industries




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 42   www.kuka.com
 CAMROB – Potential Markets

Foundries
                             sand-
Construction of molds by sand-cast and milling. In the foundry industry, most
of this task still carry out manually & it is expensive yet time consuming
  Milling of lost cores is unique task for foundry industries.
  The core is milled out of foam and will dissappear while casting.
  Bi      t      id ll t b      ill d i        b t
  Big parts are ideally to be milled using a robot




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 43   www.kuka.com
 CAMROB – Potential Markets

Woodworking
Milling of complex 2D or 3D wood structure
   Artistic products
   Furnitures
   Ornaments, Carved pilaster and capitals etc.




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 44   www.kuka.com
 CAMROB – Potential Markets

Rapid Prototyping or Modelling ( One-off Part Basis )
Many designers need fast yet affordable way to create actual size prototype,
quite often in different shapes in order to have wider selection of models
 Car seat cushion, automotive exterior and interior parts
 Windmill blades, ship body, surfboards & etc




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 45   www.kuka.com
 CAMROB – Potential Markets

                                                  3D Scanning                                3D Milling
Stone Industries
                                                                         Generate 3D Model
 Sculptures
 Restoration ( Statues )
 Grave stones
 Architectural part
 Bath tub, basin & etc




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 46           www.kuka.com
 CAMROB – Potential Markets

              KUKA-
Prototypes By KUKA-Malaysia




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 47   www.kuka.com
5. How KUKA Robotic Solutions are realized ?


                                                  Our Successful Supply Chain


                                                            End
                                                         Customers

                   and many more…




                                                                             System
                                                                           I t    t
                                                                           Integrators


                                                                                         and many more…



 KUKA Robot Group | Jan 12 & 13, 2010 | Page 48             www.kuka.com
What industrialists think & talk
        about KUKA ?
 5. Information Sharing / Discussion


Please feel free to ask me on whatever you want to know now ...
… or you can contact me later whenever your have any queries ..


                                                                              Robert Ch
                                                                              R b t Chen
                                                                             ( Regional Manager )

                                                                  Tel    : + 603 – 8063 1792
                                                                  Fax    : + 603 – 8060 0631
                                                                  Mobile : + 6016 - 229 7886
                                                                  e-mail : mschen@kuka.com.my
                                                                  Website : www.kuka.com.my




  KUKA Robot Group | Jan 12 & 13, 2010 | Page 50   www.kuka.com
KUKA Robot Group, Corporate Headquarters in Germany
                 KUKA Roboter Headquarters, Augsburg                                      Robot Manufacturing Site At Blücherstrasse




                                                     KUKA College
                                                  At Hery-Park 3000,
                                                  D-86368 Gersthofen           KUKA Robot Group                 KUKA Robot Group
                                                                             ( Global Sales Center )                    q
                                                                                                                  ( Headquarters )
                                                                                   Gersthofen          Zugspitzstraße 140, D-86165 Augsburg



 KUKA Robot Group | Jan 12 & 13, 2010 | Page 51                        www.kuka.com
KUKA Robots Origin & Products Ranges

                                                  FROM HERE ...
                                                  THE STORY OF MAKING
                                                  THE WORLD CLASS ROBOTS
                                                  HAS BEGUN .........




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 52         www.kuka.com
KUKA Robots Origin & Products Ranges

Small Robots Series




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 53   www.kuka.com
Last But Not The Least

For those who want to explore more .. Please visit us ...
                    KUKA New Building Has Been Officiated On October 9, 2008
                                                                S.E.A Countries,
                It Serves As The Main Hub For Southeast Asian ( S E A ) Countries
             In Order To Provide Better & Closer Support to Our Valuable Customers




 KUKA Robot Group | Jan 12 & 13, 2010 | Page 54   www.kuka.com
                                                 Thank You !




KUKA Robot Group | Jan 12 & 13, 2010 | Page 55     www.kuka.com

				
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