A new robot controller from FANUC now allows industrial robots to demonstrate their full performance capabilities.

FANUC’s new R 30iB controller’s new features and those that have been optimized may be summarized under four headings:

• Dimensions: The new controller is much smaller than its predecessor.
• Energy savings:  The new controller conserves energy, utilizes power inputs better, and allows the power dissipated during the braking of drives to be optionally recuperated.
• User friendliness:  The new controller comes equipped with enhanced functions, improved “Help” support via additional keys on its, nevertheless lighter, “iPendant Touch” remote-control unit, and optimized 3D representations.
• Compatibility: The new controller will run any and all programs run on its predecessor, without need for any reprogramming or other changes to the programs.

The model designation of the new robot controller, R 30iB, underscores its close relationship to FANUC’s latest CNC controller. A conspicuous feature of the new R 30iB’s exterior is its nearly 70 % smaller equipment rack. Since it has a footprint of just 600 mm wide x 470 mm deep, units may now be stacked, which conserves floor space whenever several units are in use simultaneously.

The new controller combines the latest in drive technology and economical, efficient, energy utilization with simple-to-use, versatile, and proven robotic technology. The new controller generation’s advanced drive-control system is characterized by its high-performance processors, compact drive amplifiers covering all robot axes, and greatly reduced power dissipation. The controller’s internal communications now also proceed faster, thanks to the employment of faster processors.
Its economical utilization of power inputs starts off with its “iPendant Touch,” hand-held, remote-control unit that, in spite of its added functions, gets by with 10 % lower power inputs.

The R 30iB is a veritable “energy-saving machine.” FANUC has been equipping its robot controllers with energy-saving functions since the 1990s. Rapid startups of FANUC’s operating system, saving programs in CMOS memories in the event of power outages, along with a central control for starting up and shutting down interfaced robots have already proven their worth in terms of energy savings at automobile plants. Unlike Windows-based controllers, FANUC controllers may be switched on and off without loss of data, which is a major plus.

Many of the new controller’s new functions have been configured for lower power dissipations, and existing functions have been improved in that respect. For example, the motors on robots will be switched off after a preset time interval has elapsed following their being halted, instead of being electrically held in position, which wastes energy. The superordinated system-PLC may also be switched off and on again, which conserves energy during operation in standby mode. The interfaced robots will be fully ready for use 60 seconds after being switched back on, and may then resume operation at precisely that point in the program where they left off when the PLC was switched off. The “Motion Optimization” function optimizes robot motions, avoids unnecessary robot motions, and also conserves energy. The power inputs to drives are optimally utilized due to a roboguide function designated “Power Optimization” that allows either, within certain bounds, guiding a prescribed cycle toward lower power dissipation or optimizing cycle times for given power inputs. On test, energy savings of the order of 15 % have been measured.

A power-supply unit that allows recuperation of the energy dissipated during the braking of robot drives and returning it to the system is optionally available. As in the latest-generation of Formula 1 cars, that energy may be reused for the next acceleration.

Gaining acceptance through simple operation
Gaining acceptance is closely related to how simply robots may be operated. FANUC thus made user friendliness a focal point in the development of its new R 30iB controller as well, and implemented improvements in both the controller and its hand-held “iPendant Touch” remote-control unit. Outwardly, the new “iPendant Touch” is recognizable by its somewhat larger monitor, additional function keys, and “Help” key marked with an “i.” The new hand-held unit is also 10 % lighter than its predecessor.

Function keys for controlling external seventh and eighth axes have been added to the “iPendant Touch.” There is now a “Help” key marked with an “i” that allows users to view instructions contained in the manual at any time. The new “iPendant Touch” also allows optionally displaying a single window, or two or three windows next to one another.

The new “iPendant Touch” is capable of displaying any and all model representations in the form of isometric views (3D graphics mode), which, for example, simplifies the practice-oriented observation of program steps, and is much more clearly illustrative that purely 2D representations. A number of other new functions aid the realistic display of robot motional sequences and cycles. The “NodeMap” function allows displaying robot-hand positions and trajectories in the form of points and lines, which allows recognizing potentially erroneous motions leading to collisions prior to program startup. The “Visual Jog” key allows virtually conducting a robot motion, assessing it, and optimizing it. The isometric views provided by the new “iPendant Touch” unit help make configuring the interaction between robots and their operator more secure. FANUC’s TÜV certified “Dual-Check Safety” software was featured on the predecessor remote-control unit. A new feature on the new version is 3D representation, which provide greater safety margins in both specifying safety zones and monitoring robot operations, since safety zones will be displayed in the form of virtual spheres.

Numerous other improvements simplify programming and implementing automation, without need for further PLCs or further visualization facilities.
Also among the improvements that have been implemented on the new “iPendant Touch” hand-held, remote-control unit are that its touch-screen may be customized to suit users’ needs, which will prove helpful in routine use whenever certain subsystems need to be frequently observed or fine-tuned. Programmers and operating personnel will learn to appreciate that, because it may relieve them from the need to perform many, routine, manual interventions. Programming instructions and display functions, e.g., HTML pages, have also been generally streamlined.

All of the measures that have been undertaken in order to conserve energy or improve user friendliness unfurl their full effectiveness exclusively in conjunction with the opportunities that the new R 30iB provides for improving productivity. Properly employed, “Robot Optimization” can lead to shorter cycle times. Another new feature is the “Learning Vibration Control” function (LVC function), under which an temporary mounted accelerometer on the robot’s tool measures the forces acting on its tool and activates the robot controller in order to allow optimizing the trajectory of its hand. Such trajectory optimization results in “softer” motional sequences involving lower expenditures of energy and, simultaneously, achieving a shortening of cycle times by as much as 15 %, depending upon the particular application involved. The more starts, stops, or changes of direction involved, the greater will be the effect of the LVC function on cycle times. Once trajectories have been optimized, the LVC sensor will be dismounted, since it will no longer be needed during normal manufacturing operations.
 

EDITORIAL RESPONSIBILITY IS HELD BY: FANUC Robotics Deutschland GmbH