Uses of robotic tools in manufacturing and how it enhances industrial automation
What is a robotic tool changer and what it brings to the industry?
As manufacturing process is becoming more and more complex, several tools are involved in many single production lines. In order to achieve automation, a robotic tool changer is necessary.
Robotic tool changer is a small component of a robot or robotic machine, but without it there is no flexibility at all. A typical robotic tool changer consists of a master plate and a tool plate, with the former connected to a robot and the latter to end effectors like grippers, welders and sprayers as mentioned before. Both ends of the tool changer are locked pneumatically so end effectors can be switched from time to time effectively. It also allows electrical signals, pneumatic or water to pass, thus providing utilities for tools.
Robotic tool changer adds flexibility to any manufacturing process. It allows more tools to be used in a more seamless manner when compared to manual tool changing. Manufacturers can have products with more variety and complexity without a sharp increase of manpower. The use of tool changer can save idle nonproductive time that is used to change end effectors by human operators, and can greatly reduce errors and accidents from occurring in the process. As a result, production cost is reduced as efficiency is improved both in the sense of quality and quantity. Manufacturers can gain a stronger competitive edge and achieve a higher revenue as productivity is increased with the fully automated manufacturing process.
Robots have been a significant workforce in industrial manufacturing for many decades. As manufacturers keep looking for ways to optimize productivity, new and innovative robotic tools are invented and applied in wide variety of industries today.
What are some of the common robotic tools?
A robotic tool, or technically speaking an end effector, is a very critical part of a robot, as it defines the functionality of it. There are many types of robotic tools, and some of the most commonly used are described as follows:
1.Welder
This tool is used to fuse two pieces of metal by melting a localized area with electricity, and spot welding is a common way to do it. This technique is first introduced to the automotive industry, and is widely used in different areas and has taken a major portion of welding tasks from manual laborers.
2.Gripper
Mechanical or pneumatic grippers are used to pick up and move materials, in some cases, suction cups are used to handle delicate objects. This tool is useful in many areas, like packaging, warehouse, agriculture, food and beverage and pharmaceuticals, etc.
3.Sprayer
A spraying equipment can be used in plastic and chemical industry, as it involves cleaning process for big tanks used to store toxic and dangerous chemicals. Robots with sprayer can handle the cleaning task safely. Another usages include painting in construction and automotive, and pesticide spraying in agriculture.
4.Force sensor
Also known as force-torque sensor, this tool can help to measure the force and the torque that need to be applied by the robot, thus allowing it to detect and process touch signals. Some typical applications of force sensor are assembly, grinding, deburring and sanding.
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What are some of the important features of a robotic tool changer?
Considering the role of a robotic tool changer in an automated production process, it needs to carry the following features to optimize its functions:
1.Flexibility: A robotic tool changer is better to consist electrical, pneumatic and fluid modules at the same time. This allows the tool changer to support a wider range of applications which use different types of utilities and offers a great flexibility to any single production line.
2.Locking mechanism: A fail-safe locking mechanism can prevent accidental unlocking when the air pressure is lost because of gravity, acceleration or vibration. This is achieved by using a multi-tapered cam to trap the stainless steel locking balls in the master plate, stopping it from moving and thus maintaining the locking position of tool plate and master plate.
3.High repeatability: Repeatability should come with correct alignment of master plate and tool plate, as tool changing takes place frequently, especially when many end effectors are involved in the process. Typically, robotic tool changers are required to pass the million-cycle testing at rated load in order to be accepted as having high repeatability.
4.Compact: A robotic tool changer is complicated, it has components like master plate, tool plate, piston, cam, bearing race and locking balls. Also, it is designed to pass utilities like electrical signals, water and pneumatic. A good piece of tool changer should be as compact and light as possible so it won’t be too burdensome for the robot.
LTC-0005A ROBOT TOOL CHANGER
Model: LTC-0005A
payload: 5kg
payload: 13.2N·m
payload: 18N·m
Robot Side PO: 0120
ModelMaster plateLTC-0005AMTool plateLTC-0005ATLoadPayload capacity5kg（when pressure 0.49Mpa）Allowable moment770N（Static）Allowable moment13.2N·m（Static）Allowable torque18N·mSize and precisionHousing diameterφ46mmCombined profile30mmPosition repeatability±0.015mmAir Pressure for working0.4~0.7MpaLocking mechanismLocking steel ballTexture of materialMain body materialAluminum alloyLocking mechanismAlloy steelEnvironmental ScienceTemperature0-60℃Humidity95%WeightMaster side0.11kgTool side0.04kgAir connectorPneumatic port4 x M5Max pressure0.8Mpa
Diamond Member
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LTC-0010F ROBOT TOOL CHANGER
Model: LTC-0010F
playload: 10kg
playload: 26.5N·m
playload: 35.7N·m
Robot Side PO: 0146
Model Master plateLTC-0010FM Tool plateLTC-0010FTload Payload capacity10kg（when pressure 0.49Mpa）Allowable moment1193N (static)Allowable moment26.5N·m (static)Allowable torque35.7N·mSize and precision Housing diameterφ60mm Combined profile42mm Position repeatability±0.02mmAir pressure for working0.4~0.7MpaLocking mechanismLocking steel ballTexture of materialMain body materialAluminum alloyLocking mechanismAlloy steelEnvironmental ScienceTemperature0-60℃Humidity95%WeightMaster side0.24kgTool side0.09kgAir connectorPneumatic port6 x M5Max pressure0.8Mpa
LTC-0070B ROBOT TOOL CHANGER
Model: LTC-0070B
payload: 70kg
payload: 328.5N·m
payload: 451N·m
Robot Side PO: 0136
Standard configuration: Master plate lock/unlock sensor, tool plate in position detection sensorModelMaster plateLTC-0070BMTool plateLTC-0070BTloadPayload capacity70kg（when pressure 0.49Mpa）Allowable moment9973N(Static)Allowable moment328.5N·m(Static)Allowable torque451N·mSize and precisionHousing diameterφ138mmCombined profile74mmPosition repeatability±0.02mmAir pressure for working0.4~0.7MpaLocking mechanismLocking steel ballTexture of materialMain body materialAluminum alloyLocking mechanismAlloy steelEnvironmental ScienceTemperature0-60℃Humidity95%WeightMaster side1.83kgTool side1.14kgAir connectorPneumatic port6 x PT1/8Max pressure0.8MpaElectrical Module7 pins signal modulePO05910592photoModelLMO-E16-MS07-AF01Spec5A*7pins+3A*1pins groundWeight0.23kg0.19kg
LTC-0020D TOOL CHANGER
Model: LTC-0020D
payload: 20kg
payload: 58.6N·m
payload: 80N·m
Robot Side PO: 0122
Standard configuration: Master plate lock/unlock sensor, tool plate in position detection sensorModelMaster plateLTC-0020DMTool plateLTC-0020DTloadPayload capacity20kgLocking force（When pressure 0.49Mpa）Allowable moment2514N(Static)Allowable moment58.6N·m(Static)Allowable torque80N·m Size and precisionHousing diameterφ85mmCombined profile57mmPosition repeatability±0.02mmAir pressure for working0.4~0.7MpaLocking mechanismLocking steel ballTexture of materialMain body materialAluminum alloyLocking mechanismAlloy steelEnvironmental ScienceTemperature0-60℃Humidity0-95%WeightMaster side0.53kgTool side0.30kgAir connectorPneumatic port12 x M5Max pressure0.8Mpa
LTC-0040A ROBOT TOOL CHANGER
Model: LTC-0040A
payload: 40kg
payload: 216N·m
payload: 228N·m
Robot Side PO: 0135
Standard configuration: Master plate lock/unlock sensor, tool plate in position detection sensorModelMaster plateLTC-0040AMTool plateLTC-0040ATloadPayload capacity40kg（when pressure 0.49Mpa）Allowable moment7497N（Static） Allowable moment216N·m（Static） Allowable torque228N·mSize and precisionHousing diameterφ115mmCombined profile73mmPosition repeatability±0.02mmAir pressure for working0.4~0.7MpaLocking mechanismLocking steel ballTexture of materialMain body materialAluminum alloyLocking mechanismAlloy steelEnvironmental ScienceTemperature0-60℃Humidity95%WeightMaster side1.28kgTool side0.8kgAir connectorPneumatic port8 x PT1/8Max pressure0.8Mpa
LTC-0010E ROBOT TOOL CHANGER
Model: LTC-0010E
payload: 10kg
payload: 26.5N·m
payload: 35.7N
Robot Side PO: 0134
Standard configuration: Master plate lock/unlock sensor, tool plate in position detection sensorModel Master plateLTC-0010EM Tool plateLTC-0010ETload Payload capacity10kg（when pressure 0.49Mpa）Allowable moment1193N (static)Allowable moment26.5N·m (static)Allowable torque35.7N·mSize and precision Housing diameterφ60mm Combined profile55mm Position repeatability±0.02mmAir pressure for working0.4~0.7MpaLocking mechanismLocking steel ballTexture of materialMain body materialAluminum alloyLocking mechanismAlloy steelEnvironmental ScienceTemperature0-60℃Humidity95%WeightMaster side0.33kgTool side0.09kgAir connectorPneumatic port4 x M5Max pressure0.8Mpa
LTC-0020E ROBOT TOOL CHANGER
Model: LTC-0020E
payload: 20kg
payload: 58.6N·m
payload: 80N·m
Robot Side PO: 0148
ModelMaster plateLTC-0020EM Tool plateLTC-0020ETloadPayload capacity20kg(When pressure 0.49Mpa)Allowable moment2514N(Static)Allowable moment58.6N·m(Static)Allowable torque80N·mSize and precisionHousing diameterφ85mmCombined profile50.5mmPosition repeatability±0.02mmAir pressure for working0.4~0.7MpaLocking mechanismLocking steel ballTexture of materialMain body materialAluminum alloyLocking mechanismAlloy steelEnvironmental ScienceTemperature0-60℃Humidity95%WeightMaster side0.53kgTool side0.30kgAir connectorPneumatic port12 x M5Max pressure0.8Mpa
LTC-0070A ROBOT TOOL CHANGER
Model: LTC-0070A
payload: 70kg
payload: 328.5N·m
payload: 451N·m
Robot Side PO: 0136
Standard configuration: Master plate lock/unlock sensor, tool plate in position detection sensorModelMaster plateLTC-0070AMTool plateLTC-0070ATloadPayload capacity70kg（when pressure 0.49Mpa）Allowable moment9973N(Static)Allowable moment328.5N·m(Static)Allowable torque451N·mSize and precisionHousing diameterφ138mmCombined profile74mmPosition repeatability±0.02mmAir pressure for working0.4~0.7MpaLocking mechanismLocking steel ballTexture of materialMain body materialAluminum alloyLocking mechanismAlloy steelEnvironmental ScienceTemperature0-60℃Humidity95%WeightMaster side1.83kgTool side1.14kgAir connectorPneumatic port8 x PT1/8Max pressure0.8Mpa
LTC-0120C Tool Changer
Model: LTC-0120C
Robot Side PO: 0137
Tool Side PO: 0237
payload: 842N·m
payload: 1200N·m
Standard configuration: Master plate lock/unlock sensor, tool plate in position detection sensor.ModelMaster plateLTC-0120CMTool plateLTC-0120CTloadPayload capacity120kg（when pressure 0.49Mpa）Allowable moment15407N（Static） Allowable moment842N·m（Static） Allowable torque1200N·mSize and precisionHousing diameterφ168mmCombined profile83mmPosition repeatability±0.02mmAir pressure for working0.4~0.7MpaLocking mechanismLocking steel ballTexture of materialMain body materialAluminum alloyLocking mechanismAlloy steelEnvironmental ScienceTemperature0-60℃Humidity95%WeightMaster side2.28kgTool side1.58kgAir connectorPneumatic port10 x PT1/8Max pressure0.8Mpa