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Automation - Level 2: Complex Automation

Does it make sense to further elevate the complexity of automation, and what are the potential benefi ts?
The answer to this question is dependent on what the target production volume needs are for a specifi c manufacturing
process. The effectiveness and potential gains of the (x1) robot servicing more than (x1) machine diminish with the
increased burden placed on the operator related to programming with the traditional robot as a slave confi guration.
To enable higher levels of production, a re-think of the automation cell layout is needed, and this also requires an
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upgrade to how all the programming is sequenced together.
To facilitate more practical automated operation among multiple machines, the robot must become the primary
driving source that coordinates all information. With this change-up, the robot becomes the master and the
machine(s) the slave(s). This confi guration allows the robot to become the full conductor over the entire cell,
meaning it controls and tells the machine(s) what program to run with what workpiece pallet.
The change in how the automated cell is driven
from the robot-side does alter the NC program-
ming methods, but the biggest change is that the
NC programs are now stored and reside within
the robot. The NC programs will no longer defi ne
or contain the callouts for what machine or work
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pallets are being used. This subtle modifi cation
allows the robot the fl exibility to PUSH a work-
piece and program to an available machine for
execution providing greater productivity and
machine utilization -see Figure 2.

With this revised automation confi guration, the
robot has the control and oversight to drive work
and programs to the machines. This unlinks the
Figure 2
connection between the NC program and the
workpiece pallet, but the use of special cell control software and a dedicated computer from the robot-side is added.
It is with this cell control software that the operator links what pallet (workpiece) and program are to be sequenced
together, and the robot transfers this data together to an available machine.
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The system is utilizing similar communication methods as discussed previously, but more data is being transferred
by the robot. When the robot loads a new workpiece pallet into the machine, it also loads and transfers the NC
program to the machine for execution. The cell control software becomes the brains of the operation and provides
oversight of the entire system, and this includes the ability to monitor and change the status of all programs.
In most cases, the cell control software becomes a supplied element from the robot manufacturer. With the robot
master automation confi guration, a cell control software (dedicated PC) is required, and it is the PC software that
reigns complete control over all actions. This integral cell control software provides the operator with a single
command point to interact and run the cell, as the software organizes, manages, and sequences all data related to
machine operation as well as part/pallet storage. Examples of cell control software are the CellManager, Workshop
Manager from System 3R, or JMS from EROWA.
When implementing this more advanced automation
confi guration, the operator’s behavior and daily tasks change.
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The operator typically becomes more of a software systems
expert and takes responsibility for all programming and
planned production processes running everything through
the cell controller. The operator now primarily interfaces with
the robot and cell control software rather than performing
tasks directly on the machines For example, the operator
has the ability to edit programs and change offsets directly
on the machine with the machine master confi guration, but
when using a cell controller (machine slave), all edits and
changes must be performed through the cell control software
and then be transferred to the machines. The point being that
the robot master automation confi guration becomes more of
a “hands off the machine” approach for the operator, with all Figure 3
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focus and attention to driving the system entirely from the
cell control software – see Figure 3.
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