WHAT DOES YASKAWA LEVANTO?
Yaskawa Levanto improves the capacity of all conventional sheet cutter lines and eliminates all heavy, dirty, unhealthy and repetitive human working activities. This improves the working environment and the productivity of the operators.
Yaskawa Levanto & the skilled operator
Yaskawa Levanto is the world’s first co-worker robot-cell for moving a stack of sheets from a pile to a vibration table at a sheet cutter line, while it at the same time gives the operator full control over the separation-, airing- and moving processes in relation to stack thickness, degree of airing, intensity and time of vibration and much more. Yaskawa Levanto profits from the skilled operators’ experience and knowledge in sheet handling, while it, at the same time, stores the same experiences for future use. The operator profits from Yaskawa Levanto’s strength and consistent lifting capacity. In this way the operators can use their professional skills to cut the piles as fast as possible instead of performing time-consuming, heavy, repetitive work. A pure win-win situation.
The dual-arm Motoman SDA 20 robot
Yaskawa Levanto is based on Yaskawa’s dual-arm humanoid Motoman SDA 20 robot, which is the only robot in the world, which can copy the skilled operators’ movements of twisting the sheets in relation to each other in more directions at the same time to perform an efficient separation and airing of all sheets in a stack. We call this the human diagonal twist, a process, which we have patented.
The Yaskawa Levanto robot cell
Yaskawa Levanto’s standard configuration contains of Yaskawa’s:
- Pallet lifting table with access from two sides
- Motoman SDA 20 industrial, humanoid robot
- Lifting socket
- Modified vibration table
- Automatic transport system between vibration table and sheet cutter
- Interactive, computer controlled operating system
The Motoman SDA 20 robot is positioned on a socket behind the vibration table to occupy minimal space and secure that the operator and the robot are in different, separated areas. This configuration allows the operator to work freely in his area, while the robot works in its area.
- Conveyor system for non-stop feeding of full pallets to- and removal of empty pallet from the lifting table
- Integrated pile (stack) turning
HMI touch panel – for interactive control of the robot cell
The HMI – Human Machine Interface – is an interactive color touch-screen and a PC. All important settings of Yaskawa Levanto – the speed of Motoman SDA 20, the gripper- and the vibration table settings are controlled via the touch-screen. This allows the operator to control the total sheet handling process based on his personal skills and experiences.
All job information can be keyed in via the touch-screen and all relevant job information can be stored as well as a log of all activities. With an appropriate interface job data can be collected from and supplied to the workflow system.
Yaskawa lifting table
Yaskawa’s lifting table is accessible from two sides. The operator- or the optional conveyor system - can feed the lifting table from one side, while the Motoman SDA 20 robot empties the pile from the other side.
Yaskawa Levanto 106s lifting table is configured to handle sheets of up to 76*106 cm and a pile height of up to 135 cm - plus a 15 cm pallet. Versions for higher piles are available on request.
The lifting table is equipped with Yaskawa servo-motors and controllers and is controlled by Yaskawa Levanto.
The lifting table has lock-bars which prevents sheets from sliding out of position while the Motoman SDA 20 robot manipulates the sheets.
Motoman SDA dual-arm humanoid robot
The core of the robot-cell is the Motoman SDA 20 robot. In the Yaskawa Levanto 106 cell the Motoman SDA 20 robot can handle sheets between 50*70 cm (28”) and 76*106 cm (41”). It can lift stacks of up to 30 kg and has a cycle time of around 20 seconds – subject to substrate quality.
Yaskawa Levanto’s grippers are designed to copy the functions of the human hand.
The big lower gripper, which resembles the palm of the hand, has a sharp edge, which carefully separates the wished stack from the pile below. The lower gripper is equipped with ionozised air to prevent anti-static tensions from keeping the sheets together, and a thread pad made of a polymer material prevents marking of the sheets. The area of the lower gripper, which is in contact with the sharp edges of the sheets, is made of stainless steel to prevent wear and tear.
The upper gripper, which resembles the thumb, is made of a polymer material and can turn around its axis to prevent marking under pressure.
The maximal gripper capacity is 40 mm, but the elaborated stack thickness depends on the quality of the substrate.
The Motoman SDA 20 robot is installed on a vertical socket behind the vibration table to allow it to perform a vertical movement of up to 100 cm in Yaskawa Levanto 106. This vertical movement is required to let the Motoman SDA 20 robot lift sheets of the maximum size to a vertical position and deliver the sheets carefully and accurate at the vibration table.
Having the robot on a socket behind the vibration table separates the robot area from the operator area and allows the operator to move freely in front of the sheet cutter line, while the Motoman SDA 20 robot operates freely behind the vibration table.
Turntable under the vibration table
A turntable is installed under the vibration table so it can be turned 180º so the Motoman SDA 20 robot can access the vibration from its front. Without turning the vibration table, the operator can operate it in the conventional way.
With the Motoman SDA 20 robot installed behind the vibration table, the feeding of the vibration table can be performed from the back side, if the vibration table is not turned 180ᵒ. Feeding the ream to the vibratioon table from the back side implies an integrated stack turning, which eliminates the required pile-turning in connection with handling of f.ex magazine covers with coatings.
The position of the vibration table is controlled from by Yaskawa Levanto’ touch screen.
The vibration table is a highly modified standard vibration table.
The total control system is modified by Yaskawa, and all motors are from Yaskawa, so all the vibration table’s functions are controlled by Yaskawa Levanto.
Start and stop of the vibration process is controlled by the robot as well as the vibration intensity.
The vibration table is equipped with special bars to control the position of the sheets during the delivery.
The vibration table can be operated manually in case the operator wants to handle jobs in a specific way.
Automatic stack transport system and air tables
A part of the normal operator job is to collect the vibrated stack on the vibration table and push it to the sheet cutter.
An automatic transport system, which takes the vibrated stack from the vibration table and to the side table of the sheet cutter can be installed. As soon as the vibration process is finished the transport gripper collects the stack at the vibration table and transports it on an air-cushion table to a position on an intermediary storage table. As soon as the operator wants the stack on the side table he asks for it and it is delivered to the sheet cutter’s side table.
This system performs the time-consuming and heavy job of pushing the heavy stack to the sheet cutter so the operator can focus all his time on the central job: cutting stacks.
Conveyor feeding of lifting table
The Yaskawa lifting table can be equipped with a conveyor system with an upper and lower conveyor so the system both feeds the lifting table with new pallets and empties it for empty pallets.
The conveyor system changes pallets much faster than the operator can perform it, and it eliminates the operator for wasting his time for pallet changes, so it increases the productivity of the sheet cutter line significantly.
The control of the conveyor system is performed by Yaskawa Levanto. The only manual activities are to put new pallets on the conveyor and remove the empty pallets from the lower conveyor.
The length of the conveyor system determines its storage capacity of new pallets. The standard version holds 3 pallets.
Ream turning bars and software
Feeding the ream to the vibration table from the back side requires a sophisticated turning bar system and software.
On this side
- What does Yaskawa Levanto?
- Yaskawa Levanto & the skilled operator
- The dual-arm Motoman SDA 20 robot
- The Yaskawa Levanto robot cell
- HMI touch panel – for interactive control of the robot cell
- Yaskawa lifting table
- Motoman SDA dual-arm humanoid robot
- Yaskawa socket
- Turntable under the vibration table
- Integrated stack-turning
- Vibration table
- Automatic stack transport system and air tables
- Conveyor feeding of lifting table
- Ream turning bars and software