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ABB's Stepper Conveying Line Tracking (ICC) technology empowers robots to precisely follow workpieces on moving conveyor belts. The stepper conveyor consists of evenly spaced barriers where workpieces are placed. To pick up a workpiece from these barriers, the conveyor needs to pause momentarily before quickly advancing to the next position. This quick stop-and-move action is referred to as "stepping." While the stepper conveyor is in motion, the robot tracks the workpiece with remarkable precision, regardless of any changes in the conveyor's speed.
ABB's ICC technology is particularly well-suited for applications requiring batch processing of standardized items. Typically, in a "box-loading" scenario, the loading line places objects onto the stepper conveyor at a rapid pace. The robot then retrieves these objects and transfers them to the unloading line.
One of the standout features of ICC technology is its ability to perform high-speed, precise tracking. The stepper conveyor operates as an extension of the ABB robot, driven by an ABB servo motor and controlled directly by the robot’s system. This seamless integration ensures synchronized, high-speed operations without the need for additional encoders or encoder boards. Even at high speeds, the system maintains accuracy, with linear acceleration reaching up to 12,000 mm/s².
Key Features:
- Compatible with all ABB IRB 360 series robots.
- Up to two IRB 360 robots can operate independently on separate stepper conveyor lines in a MultiMove setup.
- Supports up to two stepper conveyor lines and two regular conveyor lines simultaneously, allowing dynamic switching between them.
- The stepper conveyor line is controlled entirely by the robot system, eliminating the need for an encoder board.
- Synchronization is triggered via a digital signal when a new object enters the system.
- Up to 100 objects can be queued and managed using RAPID instructions, with the option to define specific start-up windows for tracking.
- Maximum tracking distances can be pre-set.
- Tracking can be initiated mid-operation without stopping.
- Can function independently or alongside PickMaster 3.
An exemplary case showcasing ICC technology is the Mengniu ice cream packaging project. This system employs one ABB IRB 360-8/1130 industrial robot with a dual-line ice cream packaging setup, including a supporting fixture, robot bracket, stepper product conveyor line equipped with ICC, and a product acceleration conveyor line.
Technical Specifications for the Robot:
- Model: IRB 360-8/1130
- Wrist Payload: 8 kg
- Maximum Reach: 1.13 m
- Number of Axes: 4
- Protection Rating: IP54
- Installation Method: Can be mounted upside-down
- Repeatability: ±0.07 mm
- Power Supply: 3-phase 400V (+10%, -15%), 50Hz
- Rated Power: 4 KVA
- Operating Temperature: 5°C to 45°C
- Relative Humidity: Up to 95%
- Noise Level: <70 dB
Fixture Details:
- Comprises mechanical components and vacuum systems.
- Can pick up 5 or 10 products at a time.
- Offers multiple methods for product handling, such as single or double-box picking.
- Highly adaptable, capable of handling dozens of product specifications seamlessly.
Fixture Innovation:
The fixture's advanced design addresses differences in product spacing between the stepper conveyor and post-boxing stages. By leveraging the robot’s fourth axis as a telescopic power source, the fixture's weight is reduced, enhancing stability and operational efficiency.
Stepper Product Conveyor Line:
- Driven by an ABB servo motor, ensuring precise control over speed and movement.
- Ensures synchronized movement between the robot and conveyor line, enabling accurate tracking.
- Barrier width adjustments are infinitely customizable within the design parameters, offering superior flexibility.
Product Acceleration Conveyor Line:
- Positioned at the front of the stepper conveyor line, accelerating product delivery to the stepper line.
- Increases product spacing on the upstream conveyor, facilitating orderly entry into the stepper line.
Advantages of the Packaging Solution:
- Single robot output exceeds 400 units per minute.
- Compact design with high integration, allowing two stepper lines to be supported by a single IRB 360 robot while minimizing floor space.
- Cost-effective compared to traditional setups, which typically require two servo motors for a single stepper line.
- Flexible design with infinite adjustability of barrier widths and strong compatibility for various product types.
- Automatic control of fixture opening and closing via the robot’s fourth axis, reducing fixture weight and improving stability.
- Proprietary patents covering all related technologies ensure a unique and comprehensive solution.