Quickly convertible and suitable for a wide range of applications - these were also Lenkering's requirements for an automation solution. The company from Steinfeld in Lower Saxony specializes in special machine construction and machining technology and supports customers from the automotive, plastics and hygiene industries with robot-based automation. Potential customers are uncertain as to whether they can use the robots in a sufficiently versatile and frequent manner. The Lenkering team therefore set about developing a robot-based application that is versatile and thus minimizes downtimes.

The result is a mobile robot solution in which a KR Agilus machine is installed on a mobile frame. During operation, the application is surrounded by protective fence elements that can be removed without tools for safety reasons. Customers want a cost-effective and automated solution that can be used flexibly and can also be used in confined working spaces.

The KR Agilus is an all-rounder. The solution developed by Lenkering can be moved from one workstation to another. What's more, the KR Agilus can be easily converted for different tasks. Thanks to the different fields of activity, the user can reduce downtimes and amortize the investment costs in the foreseeable future. The KR 6 R900 robot actually installed achieves maximum repeat accuracy and continuous precision thanks to its robust design. Lenkering deliberately chose this small robot because it can work together with production machines. The KR Agilus performs pick-and-place tasks as well as assembly work on components after they have been processed by the machine tools. The assembly tasks include joining plastic assemblies.

Lenkering realized the mobile application in collaboration with Item. © Steering ring

Close cooperation with various production machines is required for pick-and-place tasks. The robot takes over the further processing of components, for example by packaging them or testing their quality. For quality assurance, the robot works together with camera systems, among other things. This makes it possible to check finished components for completeness. Each activity of the robot is already defined in advance in the PLC. The robot knows which tool it is currently using through appropriate coding. If this tool does not match the newly selected activity, the robot replaces it independently. The quick changeover is carried out using a quick-change grip system. The robot application is equipped with the Kuka Load Data Determination and Kuka Gripper&Spottech software packages for smooth changeover and handling of different tools.

Safety was a key aspect in the development of the application. It was necessary to ensure the safety of the employees, the protection of the robot and the greatest possible freedom for the robot to carry out its activities. At the same time, the workspace had to be as small as possible and the system as a whole had to be able to be dismantled quickly - for example, in case the space is needed elsewhere or the machining process has been completed. This is made possible by the use of aluminum profiles from Item. In this particular case, the customer required the frame to cover a protective area of 1,250 by 1,750 millimetres. Because narrow passages also had to be negotiated, the platform was not allowed to exceed 700 by 1,200 millimetres during transport. In collaboration with Item, these specifications could be implemented; the profiles from the Item modular system are lightweight, quick to assemble and dismantle and have an attractive design. It takes just eight minutes to dismantle the frame, including the communication cable, and reassemble it at a different location. The modular components are expandable. pb