Loading and unloading a lathe with hexagonal steel blocks, which are then formed into the cylindrical shape of a bolt, is an everyday task in metalworking companies. However, it is one that is physically demanding and monotonous. The Mairo-Flex iisy, a modular automation cell from Mairotec, performs this task reliably and tirelessly. At its heart is the Kuka Cobot LBR iisy 11.

"The need for automation in many recurring work steps is increasing, especially in SMEs and craft businesses," explains Andreas Mathes, founder and Managing Director of Mairotec from Ilmenau in Thuringia. "To get started, you need your own, highly flexible solution that everyone can afford," he adds.

Mairotec is a Kuka system partner and specializes in product and software development for automation solutions. This is how Mathes came to develop the Mairo-Flex iisy with his team and Kuka.

Let "iisy" take care of machine loading

Placing the loading and unloading of the lathe with steel bolts in the "hands" of this solution allows a company to fully automate the process. The human colleagues can devote themselves to more demanding and varied tasks. "Robots don't take away jobs," Mathes emphasizes, "they rather help to get or keep production going, for which there are fewer and fewer people available on the labour market."

The technological concept of the LBR iisy from Kuka creates the conditions for this exceptional flexibility of the automation cell. Its intuitive operability enables fast, productive use without prior knowledge. Based on the iiQKA.OS operating system, tasks are "taught" very simply by manual guidance. With the Smart-Pad pro operating device, further programming is as simple as using a smartphone. The LBR iisy's integrated cable routing and power supply also enable quick and easy tool changes. Accessories such as grippers and expert tips are particularly easy to access via the "Robotic Republic" digital ecosystem, which is part of iiQKA.OS. Mathes explains what makes integration into production even easier as follows: "The LBR iisy fulfills all essential industry standard functions such as fieldbus protocols, digital I/Os, safety and more. This means we can easily integrate the automation cell into any of our customers' existing systems."

The cobot also scores points with its remarkable joint speed, which qualifies it for a wide range of tasks. In addition to loading and unloading machines, the range of tasks also includes pick-and-place tasks, handling, packaging and quality control.

Safety: top, premiere: a success

Safety aspects played a key role in the development of both the LBR iisy and the Mairo-Flex iisy automation cell. Mathes explains: "Instead of a protective housing, we use a 360-degree radar field from inxpect for our automation cell, which surrounds the Mairo-Flex iisy like an invisible safety sphere. The system is so sensitive that it even reacts to the blink of an eye or breathing. In the event of physical movement in the safety zone, the automation cell immediately reduces its speed or stops completely and only starts up again when the track is clear."

The first use of the Mairo-Flex iisy in stud production has been a success: a zero-point pallet with 96 inserted hexagonal steels lies on the attachment fork. The robot picks these up with the gripper and inserts them precisely into the spindle, where the turning tool begins processing the stud body after the door has closed. The robot then removes the finished bolt and places it back on the pallet with millimetre precision before the next part comes its turn. "It can continue like this, around the clock," explains Andreas Mathes with satisfaction. This applies equally to the work of the Mairo-Flex iisy and to the many other automation solutions that Mathes and his team are already working on.

Experience the Mairo-Flex iisy live at the EMO ...

... from October 18 to 23, 2023 in Hanover at the Kuka stand in Hall 9, Stand D42. Get your free ticket now: www.kuka.com/emo-2023.

Jonas Micheler /red