brochure gamma comau robotics

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EN Your Robotized Solution

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Page 1: Brochure Gamma Comau Robotics

EN

Your Robotized Solution

Page 2: Brochure Gamma Comau Robotics

INDEX

3 Company Overview

6 Robots: General Purpose

12 Robots: Hollow Wrist

16 Robots: PAL - Press - SmartLaser

18 Positioners - Slides - Motors

21 Control Unit - Teach Pendant

24 Athomo Cell & Applications

31 Software Products

37 Services & Training

Page 3: Brochure Gamma Comau Robotics

Comau RoboticsComau Robotics, as a top global manufacturer of high quality industrial robots, offers a broad range of technologically advanced robotized solutions designed to maximize customer’s productivity in response to challenging market demands.A partnership with Comau means increased efficiency and productivity.Our innovative technology, integrated solutions, turn-key systems and robotized cells, supported by highly qualified systems integrators, can help businesses in the automotive industry, among others, to be more competitive in today’s increasingly fast-paced markets.

SMART Robots

Comau Robotics offers a wide range of innovative robot models, six and multi-axes articulated robots, covering all payload categories and applications. Technologically advanced, reliable, flexible, and specifically tailored to our customers’ goals, our SMART robotized solutions guarantee optimal performance in several industrial sectors.Comau Robotics features a broad selection of robot families, small, medium and high payload, robotized cells and process-integrated solutions.

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Page 4: Brochure Gamma Comau Robotics

Small/Medium payload (up to 60 kg)SMART SIX, NS, NM and New NJ 60 - SMART5 Arc4With payload from 5 kg to 60 kg, these models are typically used for arc-welding, machine tool tending, assembly, manipulating, sealing and polishing. One of the main features is high repeatability (up to 0.05 mm), suiting all applications where high speed and precision are required. SMART5 Arc4: an innovative robot family range in arc welding application, based on hollow wrist technology, with all dressing cables of the welding torch housed inside the wrist.

Robot Range

High payload (up to 270 kg)

SMART5 NJ Family: with a payload from 90 kg to 270 kg, these models represent the state of art in mechanical dressing, offering top performances in terms of lightness, speed, robustness and precision. All these models can be mounted in floor or ceiling position. Robots from this family range are available both in the “standard wrist“ version (NJ models) and in the “hollow wrist“ version (NJ4 Models). The innovative, yet long established, “hollow wrist“ technology has been further enhanced in the SMART5 NJ4 models: the entire welding dressing is housed in the forearm, rather than externally as in conventional robots. This solution guarantees an unequalled level of performance and saving in maintenance costs, allowing 100% “off-line“ robot programming. Recently introduced to the market, new SMART5 PAL is the Comau robot specifically designed for all palletizing applications (payload 180 kg and 260 kg).

Heavy Duty Payload (up to 800 kg)

Within SMART5 NJ family range, we have models for heavy-duty applications, with payload from 290 kg to 500 kg. SMART5 NJ heavy-duty models have the best-in-class ratio between max payload, up to 500 kg, and reach, 3.0 m, with a floor space-saving base. Thanks to their specific features, these robots can operate over a wide working area and can be used for several applications: handling and machining in foundry industry, spot welding, polishing, grinding, deburring, heavy-duty palletizing and pick up operations.SMART NX family: the strongest model in Comau family range.

Robotized Cells

Comau Robotics offer includes high-quality standard robotized solutions, such as the Athomo arc welding cell.

Plus, in keeping with the Comau name, we guarantee prompt and flexible after-sale service.Our highly qualified and skilled team guide and assist customers, whether it be for immediate intervention or for long-term scheduled maintenance.

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Page 5: Brochure Gamma Comau Robotics

NJ4 Robot FamilyThe effective solution for Spot Welding

Symmetrical Structure

The solution applied to the NJ4 series have privileged the perfect symmetry of the mechanical structure. There are two big advantages: specularity of the two sides of the welding line and a considerable time reduction in off-line simulation and programming.

Integrated Dressing

Comau has launched a new challenge in spot welding applications: the creation of a hollow machine containing a completely integrated dressing, so that the actual mechanical overall dimensions are never increased by external cables.

Power Saving

The manufacturing features of the new NJ4 (agile and light structure, reduced weight) allow high performance and important energy saving, up to 25% more than the other similar robots.

Year Full Warranty

The new Comau Robotics technology of the “integrated dressing” provides certainty of long duration, reduction of break-downs and savings in terms of cost for service cable replacement. That is why Comau Robotics guarantees the integrated dressing for 8 years of continuous work, on 3 shifts, 365 days per year.

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Page 6: Brochure Gamma Comau Robotics

Robots: General Purpose

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Page 7: Brochure Gamma Comau Robotics

AVAILABLE VERSIONS

PROTECTION DEGREE

ASSEMBLYPOSITION

WEIGHT (kg)

REACH (mm)

RP(mm)

LOAD(kg)

AXESMODEL

IP65Floor

CeilingTilted

(max 45°)16014000.0566

● Arc Welding● Handling / Packaging

Arc

Applications

Smart5 SiX 6-1.4

RP = Repeatability ISO 9283

● Arc Welding● Assembly● Plasma Cutting / Water Jet ● Polishing / Deburring● Handling / Packaging

7

● Arc Welding● Assembly● Plasma Cutting / Water Jet ● Polishing / Deburring● Handling / Packaging

IP65 / IP67Wrist

FloorCeilingTilted

(max 45°)33516500.05166 Hand / Arc

Foundry

Applications

Smart5 NS 16-1.65

● Arc Welding● Assembly● Cosmetic Sealing ● Laser Welding● Laser Cutting

● Plasma Cutting / Water Jet● Handling / Packaging

IP65 / IP67Wrist

FloorCeilingTilted

(max 45°)71531000.01166 Hand / Arc

Foundry

Applications

Smart5 NM 16-3.1 In-Line

Scala 1:30SMART-5 NS-12-1.85 Hand

Scala 1:30SMART-5 NS-16-1.65 Hand

Scala 1:30SMART-5 NM 16 - 3.1 HAND

Scala 1:30SMART-5 NM 25 - 2.2 (In-line)

Scala 1:30SMART-5 SiX 6-1.4

IP65 / IP67Wrist

FloorCeilingTilted

(max 45°)33518500.05126 Hand / Arc

Foundry

Applications

Smart5 NS 12-1.85

● Arc Welding● Assembly● Cosmetic Sealing ● Laser Welding● Laser Cutting

● Machine TendingMachine TendingMachine T● Measuring TestingMeasuring TestingMeasuring T● Plasma Cutting / Water Jet● Polishing / Deburring● Handling / Packaging

IP65 / IP67Wrist

FloorCeilingTilted

(max 45°)68522410.06256 Arc

Foundry

Applications

Smart5 NM 25-2.2 In-Line

Page 8: Brochure Gamma Comau Robotics

AVAILABLE VERSIONS

PROTECTION DEGREE

ASSEMBLYPOSITION

WEIGHT (kg)

REACH (mm)

RP(mm)

LOAD(kg)

AXESMODEL

IP65 / IP67Wrist

FloorCeilingTilted

(max 45°)68522410.06256

● Arc Welding● Assembly● Cosmetic Sealing● Foundry ● Laser Welding

ArcFoundry

Applications

Smart5 NM 25-2.2 Off-set

RP = Repeatability ISO 9283

IP65 / IP67Wrist

FloorCeilingTilted

(max 45°)68020000.06456 Arc

Foundry

Applications

Smart5 NM 45-2.0 Off-set

IP65 / IP67Wrist

FloorCeilingTilted

(max 45°)55022580.06606 -

Applications

Smart5 NJ 60-2.2

IP65 / IP67Wrist

FloorCeilingTilted

(max 45°)68020000.06456

ArcFoundry

Wash

Applications

Smart5 NM 45-2.0 In-line

IP65 / IP67Wrist

FloorCeiling107029800.071106 Foundry

Applications

Smart5 NJ 110-3.0

● Laser Cutting● Machine TendingMachine TendingMachine T● Measuring TestingMeasuring TestingMeasuring T● Plasma Cutting / Water Jet● Polishing / Deburring

● Handling / Packaging

● Arc Welding● Assembly● Cosmetic Sealing● Foundry ● Laser Welding

● Laser Cutting● Machine TendingMachine TendingMachine T● Measuring TestingMeasuring TestingMeasuring T● Plasma Cutting / Water Jet● Polishing / Deburring

● Handling / Packaging

● Arc Welding● Assembly● Cosmetic Sealing● Foundry ● Laser Welding

● Laser Cutting● Machine TendingMachine TendingMachine T● Measuring TestingMeasuring TestingMeasuring T● Plasma Cutting / Water Jet● Polishing / Deburring

● Handling / Packaging

● Assembly● Cosmetic Sealing● Dispensing● Foundry ● Laser Welding

● Laser Cutting● Machine TendingMachine TendingMachine T● Measuring TestingMeasuring TestingMeasuring T● Plasma Cutting / Water Jet● Press to Press

● Polishing / Deburring● Processing Machining● Handling / Packaging● Wood / Glass Machine

● Assembly● Cosmetic Sealing● Dispensing● Foundry ● Laser Welding

● Laser Cutting● Machine TendingMachine TendingMachine T● Measuring TestingMeasuring TestingMeasuring T● Plasma Cutting / Water Jet● Polishing / Deburring

● Handling / Packaging● Spot Welding

8

Scala 1:30SMART-5 NM 25 - 2.2 (In-line)

Scala 1:30SMART-5 NM 45 - 2.0 (In-line)

Scala 1:30SMART-5 NM 45 - 2.0 (In-line)

Scala 1:30SMART-5 NJ-60-2.2

Scala 1:30SMART-5 NJ-110-3.0

Page 9: Brochure Gamma Comau Robotics

AVAILABLE VERSIONS

PROTECTION DEGREE

ASSEMBLYPOSITION

WEIGHT (kg)

REACH (mm)

RP(mm)

LOAD(kg)

AXESMODEL

IP65 / IP67Wrist

FloorCeiling105026160.071306 Foundry

Applications

Smart5 NJ 130-2.6

RP = Repeatability ISO 9283

● Spot Welding● Assembly● Foundry● Handling / Packaging

9

● Spot Welding● Assembly● Foundry● Machine TendingMachine TendingMachine T● Handling / Packaging

IP65 / IP67Wrist

FloorCeiling122027010.0752206 Foundry

Applications

Smart5 NJ 220-2.7

● Spot Welding● Assembly● Foundry● Handling / Packaging● Palletizing

IP65 / IP67Wrist

FloorOn Platform143034500.11656 Foundry

Applications

Smart5 NJ 165-3.4 SH

IP65 / IP67Wrist

FloorCeiling124030000.0851656 Foundry

Applications

Smart5 NJ 165-3.0

● Spot Welding● Assembly● Foundry● Handling / Packaging

IP65 / IP67Wrist

FloorOn Platform141531510.12106 Foundry

Applications

Smart5 NJ 210-3.1 SH

● Assembly● Cosmetic Sealing● Dispensing● Foundry ● Machine TendingMachine TendingMachine T

● Measuring TestingMeasuring TestingMeasuring T● Handling / Packaging● Spot Welding

Scala 1:30SMART-5 NJ-130-2.6

3

Scala 1:30SMART-5 NJ 165-3.0

Scala 1:30SMART-5 NJ 220-2.7

Scala 1:30SMART-5 NJ 165-3.4 SH

Scala 1:30SMART-5 NJ 210-3.1 SH

Page 10: Brochure Gamma Comau Robotics

AVAILABLE VERSIONS

PROTECTION DEGREE

ASSEMBLYPOSITION

WEIGHT (kg)

REACH (mm)

RP(mm)

LOAD(kg)

AXESMODEL

IP65 / IP67WristFloor215029970.152906

● Spot Welding● Assembly● Foundry● Processing Machining● Handling / Packaging

Foundry

Applications

Smart5 NJ 290-3.0

RP = Repeatability ISO 9283

IP65 / IP67WristFloor245029970.153706 Foundry

Applications

Smart5 NJ 370-3.0

IP65 / IP67WristFloor245029970.154206 -

Applications

Smart5 NJ 420-3.0

IP65 / IP67WristFloor210027030.153706 Foundry

Applications

Smart5 NJ 370-2.7

IP65 / IP67WristFloor240027030.154506 Foundry

Applications

Smart5 NJ 450-2.7

● Machine TendingMachine TendingMachine T

● Spot Welding● Assembly● Foundry● Processing Machining● Handling / Packaging

● Machine TendingMachine TendingMachine T

● Spot Welding● Assembly● Foundry● Processing Machining● Handling / Packaging

● Machine TendingMachine TendingMachine T

● Spot Welding● Assembly● Foundry● Processing Machining● Handling / Packaging

● Machine TendingMachine TendingMachine T

● Assembly● Cosmetic Sealing● Dispensing● Foundry ● Laser Welding

● Laser Cutting● Machine TendingMachine TendingMachine T● Measuring TestingMeasuring TestingMeasuring T● Plasma Cutting / Water Jet● Polishing / Deburring

10

Scala 1:30SMART-5 NJ-290-3.0

Scala 1:30SMART-5 NJ-370-2.7

Scala 1:30SMART-5 NJ-370-3.0

Scala 1:30SMART-5 NJ-420-3.0

Scala 1:30SMART-5 NJ-450-2.7

Page 11: Brochure Gamma Comau Robotics

AVAILABLE VERSIONS

PROTECTION DEGREE

ASSEMBLYPOSITION

WEIGHT (kg)

REACH (mm)

RP(mm)

LOAD(kg)

AXESMODEL

IP65 / IP67WristFloor240027030.155006 -

Applications

Smart5 NJ 500-2.7

RP = Repeatability ISO 9283

● Assembly● Foundry

11

● Assembly● Foundry● Handling / Packaging

IP65 / IP67WristFloor590038150.28004 -

Applications

Smart5 NX 800-3.8 4A

IP65 / IP67WristFloor600030360.26006 -

Applications

Smart5 NX 600-3.0

● Spot Welding● Assembly● Handling / Packaging● Machine TendingMachine TendingMachine T

Scala 1:30SMART-5 NJ-500-2.7

Scala 1:30SMART NX1-600 ( 6 Ax.)

Scala 1:30SMART NX1-800 ( 4 Ax.)

Page 12: Brochure Gamma Comau Robotics

Robots: Hollow Wrist

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Page 13: Brochure Gamma Comau Robotics

Scala 1:30SMART-5 Arc4

Scala 1:30SMART-5 NJ4-90-2.2

Scala 1:30SMART-5 NJ4-170 - 2.5

Scala 1:30SMART-5 NJ4-90-2.2

Scala 1:30SMART-5 NJ4-170-2.9

AVAILABLE VERSIONS

PROTECTION DEGREE

ASSEMBLYPOSITION

WEIGHT (kg)

REACH (mm)

RP(mm)

LOAD(kg)

AXESMODEL

IP65Floor

CeilingTilted

37519510.0556

● Arc Welding● Assembly

Arc

Applications

Smart5 ARC4

● Spot Welding● Handling

13

● Spot Welding● Handling

IP65FloorCeiling69822100.071106 I* / TC**

Applications

Smart5 NJ4 110-2.2Smart5 NJ4 110-2.2Smart5 NJ4 110-2.2

● Spot Welding● Handling

IP65FloorCeiling110025000.11706 I* / TC**

Applications

Smart5 NJ4 170-2.5Smart5 NJ4 170-2.5Smart5 NJ4 170-2.5

IP65FloorCeiling69822100.07906 I* / TC**

Applications

Smart5 NJ4 90-2.2Smart5 NJ4 90-2.2

● Spot Welding● Handling

IP65FloorCeiling124029180.11706 I* / TC**

Applications

Smart5 NJ4 170-2.9

RP = Repeatability ISO 9283* Integrated spot welding gun** Integrated tool change

Page 14: Brochure Gamma Comau Robotics

Scala 1:30SMART-5 NJ4-220-2.7

AVAILABLE VERSIONS

PROTECTION DEGREE

ASSEMBLYPOSITION

WEIGHT (kg)

REACH (mm)

RP(mm)

LOAD(kg)

AXESMODEL

IP65 FloorCeiling108022040.11756

● Spot Welding● Handling

I* / TC**

Applications

Smart5 NJ4 175-2.2

IP65 FloorOn Platform147031880.12106 I* / TC**

Applications

Smart5 NJ4 210-3.1 SH

IP65FloorCeiling126024170.152206 I* / TC**

Applications

Smart5 NJ4 220-2.4

IP65 FloorOn Platform142033770.11656 I* / TC**

Applications

Smart5 NJ4 165-3.4 SH

IP65 FloorCeiling129027340.152206 I* / TC**

Applications

Smart5 NJ4 220-2.7Smart5 NJ4 220-2.7Smart5 NJ4 220-2.7

● Spot Welding● Handling

● Spot Welding● Handling

● Spot Welding● Handling

● Spot Welding● Handling

14 RP = Repeatability ISO 9283* Integrated spot welding gun** Integrated tool change

Scala 1:30SMART-5 NJ4-165-3.4 SH

Scala 1:30SMART-5 NJ4-175 - 2.2

Scala 1:30SMART-5 NJ4-210-3.1 SH

Scala 1:30SMART-5 NJ4-220-2.4

Page 15: Brochure Gamma Comau Robotics

AVAILABLE VERSIONS

PROTECTION DEGREE

ASSEMBLYPOSITION

WEIGHT (kg)

REACH (mm)

RP(mm)

LOAD(kg)

AXESMODEL

IP65 Floor200530020.152206 I* / TC**

Applications

Smart5 NJ4 220-3.0

● Spot Welding● Handling

15

IP65 Floor197527030.152706 I* / TC**

Applications

Smart5 NJ4 270-2.7

● Spot Welding● Handling

RP = Repeatability ISO 9283* Integrated spot welding gun** Integrated tool change

Scala 1:30SMART-5 NJ4-220 - 3.0

Scala 1:30SMART-5 NJ4-270 - 2.7

Page 16: Brochure Gamma Comau Robotics

Robots: PAL - Press - SmartLaser

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Page 17: Brochure Gamma Comau Robotics

Scala 1:30SMART-5 NJ LASER

AVAILABLE VERSIONS

PROTECTION DEGREE

ASSEMBLYPOSITION

WEIGHT (kg)

REACH (mm)

RP(mm)

LOAD(kg)

AXESMODEL

IP65Floor125031000.151804

● Handling / Packaging● Palletizing

-

Applications

Smart5 PAL 180-3.1

RP = Repeatability ISO 9283

● Handling / Packaging● Palletizing

17

● Handling / Packaging● Press to Press

IP65Floor225031000.24704 -

Applications

Smart5 PAL 470-3.1

● Handling / Packaging● Press to Press

IP65Floor127032090.171006 -

Applications

Smart5 NJ Press 100-3.2

IP65Floor125031000.152604 -

Applications

Smart5 PAL 260-3.1

● Laser Cutting● Laser Welding

IP65Floor115031000.07-7 -

Applications

Smart5LaserSmart5Laser

● Handling / Packaging● Press to Press

IP65FloorOn Platform151537000.21306 -

Applications

Smart5 NJ Press 130-3.7 SH

Scala 1:30SMART-5 PAL 180-3.1

Scala 1:30SMART-5 PAL 260-3.1

Scala 1:30SMART-5 PAL 470-3.1

Scala 1:30SMART-5 PRESS - NJ 100 - 3.2

RP = Repeatability ISO 9283

Scala 1:30SMART-5 NJ 165-3.4 SH

Page 18: Brochure Gamma Comau Robotics

Positioners - Slides - Motors

18

Page 19: Brochure Gamma Comau Robotics

1919

VERSION MAX PAYLOAD(kg)

MAX DIAMETER(mm)

MAX LENGTH(mm)

250 1.1-1.6 2x250 1100 1600

500 1.2-2.0 2x500 1200 2000

500 1.2-2.5 2x500 1200 2500

750 1.2-2.0 2x750 1200 2000

850 1.2-2.5 2x850 1200 2500

Smart5 PTDV

INFORMATIONMODEL

VERSION MAX PAYLOAD(kg)

MAX DIAMETER(mm)

MAX LENGTH(mm)

500 1.2-2.0 2x500 1200 2000

500 1.2-2.5 2x500 1200 2500

500 1.2-3.0 2x500 1200 3000

500 1.2-3.5 2x500 1200 3500

500 1.2-4.0 2x500 1200 4000

VERSION MAX PAYLOAD(kg)

MAX DIAMETER(mm)

MAX LENGTH(mm)

250 2x250 1100 1000

Smart5 PTDO

750 1.2-2.0 2x750 1200 2000

750 1.2-2.5 2x750 1200 2500

750 1.2-3.1 2x750 1200 3100

750 1.2-3.5 2x750 1200 3500

750 1.2-4.0 2x750 1200 4000

750 1.2-5.0 2x750 1200 5000

VERSION MAX PAYLOAD(kg)

MAX DIAMETER(mm)

MAX LENGTH(mm)

1000 1000 1100 800

Smart5 PTSORB

250 1.1-1.6 2x250

500 1.2-2.0 2x500

500 1.2-2.5 2x500

750 1.2-2.0 2x750

850 1.2-2.5 2x850

VERSION MAX PAYLOADSmart5 PTDV

500 1.2-2.0 2x500

500 1.2-2.5 2x500

500 1.2-3.0 2x500

500 1.2-3.5 2x500

500 1.2-4.0 2x500

750 1.2-2.0 2x750

750 1.2-2.5 2x750

750 1.2-3.1 2x750

750 1.2-3.5 2x750

750 1.2-4.0 2x750

750 1.2-5.0 2x750

Smart5 PTDORB

Page 20: Brochure Gamma Comau Robotics

20

Slide C5G VERSION ROBOT SPEED(m/s)

TRAVEL LENGHT(m)

TM-52 NS 1.6 2 ÷ 30

TM-72 NM - NJ LIGHT 1.6 2 ÷ 30

TM-90 NJ HEAVY 1.6 2 ÷ 30

Motors MODEL NOMINAL SPEED(rpm)

NOMINAL SPEED TORQUE(nm)

Motor 0.35 nm - C5G - IP67 5000 0.31

Motor 0.75 nm - C5G - IP65/67 4500 0.56

Motor 3.5 nm - C5G - IP65/67 4500 2.7

Motor 5 nm - C5G - IP65/67 4500 3.75

Motor 9 nm - C5G - IP65/67 4000 6.2

Motor 13 nm - C5G - IP65/67 4000 9

Motor 18 nm - C5G - IP65/67 4200 12.5

Motor 25 nm - C5G - IP65/67 3700 17.5

Motor 33 nm - C5G - IP65/67 3550 23

Motor 33 nm - C5G - IP44 -FAN 3550 23

VERSION MAX PAYLOAD(kg)

OUTPUT ROTATION SPEED (°/s)

RP AT 500 mm(mm)

1000 1000 69 0.1

3000 3000 50 0.1

4500 4500 52 0.15

6000 6500 35 0.2

VERSION MAX PAYLOAD(kg)

OUTPUT ROTATION SPEED (°/s)

RP AT 500 mm(mm)

500 500 150 0.05

1000 1000 150 0.06

1250 1250 150 0.06

2500 2500 100 0.09

5000 5000 27 0.10

Smart5 MP

Smart5 TR

MODEL INFORMATION

Slide C5G

Motors

Page 21: Brochure Gamma Comau Robotics

21

Control Unit - Teach Pendant

Page 22: Brochure Gamma Comau Robotics

22

1100 x 800 x 500 400V to 500V50/60Hz

IP54( IP2 x rear side ) All Robots

1100 x 800 x 500 400V to 500V50/60Hz

IP54( IP2 x rear side )

Two RobotsSIX or NS

Plus a Rotary Table

1700 x 800 x 500 400V to 500V50/60Hz

IP54( IP2 x rear side )

Two RobotsSIX or NS

Plus Three or FiveAxes Positioners

540 x 800 x 500 - IP54 For cell management modules integration

Special FeaturesUseProtection DegreeSizeMODEL

C5G - Robot Controller

C5G - TWIN Controller(multirobot management)

C5G - Power Controller

USEPROTECTION DEGREEELECTRICAL CONNECTIONSSIZE

H x W x D(mm)

MODEL

C5G - Empty Box

C5G - Power Controller(multirobot management)

Page 23: Brochure Gamma Comau Robotics

23

- - For all C5G control cabinet -

Screen: 6.4”Weight: 1.47 kg IP54 For all robots Selector key function

Screen: 6.4”Weight: 1.09 kg IP54 For all robots Selector key function

USEPROTECTION DEGREEELECTRICAL CONNECTIONSSIZE

H x W x D(mm)

MODEL SPECIAL FEATURESUSEPROTECTION DEGREESIZEMODEL

C5G Weels Kit

C5G - Teach Pendant Wireless

C5G - Teach Pendant Wired

Page 24: Brochure Gamma Comau Robotics

Athomo Cell & Applications

24

Page 25: Brochure Gamma Comau Robotics

25

2 SMART5 ARC4 hollow wrist robots with integrated arc welding dressing

2 Fronius TransPulse Synergic 4000 power source

SMART5 PTDV 750-2.0 double lathe positioner with vertical station changer:Payload per station: 750 kg

Distance between plates: 2000 mmRotating diameter: 1200 mm

A single C5G control unit for simultaneous, integrated control of 2 robots and positioner (15 controlled axes)

Fast fixture change

Rotary distributors for water, air and current fieldbus signal (PROFINET)

Integrated PLC to control cell, safety devices and fixtures

Siemens operator interface with 10” colour touchscreen

Perimeter safety protection

Single integrated power (380 Vac) and fluidic (air) interface

Manual load/unload area protected by certified light barrier and laser scanner

Rigid and fork-liftable cell supporting and joining frame for transport by conventional vehicles, with no need for disassembly

Maximum dimensions: 5700 mm x 4150 mm

SPECIAL VERSIONS AND OPTIONS

The Athomo cell is also available in versions with:

SMART5 PTDV 850-2.5 positioner (station payload 850 kg and distance between plates 2500 mm)

Fronius TS 4000, TS/TPS 5000 or CMT 4000 power sources

“Plug & Play“ Cell for Arc Welding

Page 26: Brochure Gamma Comau Robotics

26

DESCRIPTIONAPPLICATION

Robot Dressing - Material Handling INTEGRATED DRESSING

(for Hollow Wrist Robots)

EXTERNAL DRESSING

(for Traditional Wrist Robots)

Robot Dressing: Spot Welding INTEGRATED DRESSING

(for Hollow Wrist Robots)

EXTERNAL DRESSING

(for Traditional Wrist Robots)

Runs completely inside robot arm and trough the wrist

8 Year warranty

100% OLP

Different fieldbus communication supported

1/2” air hose

Payload and range from 90-2.2 to 270-2.7

Dressing runs inside robot arm structure from base till axes 3

External dressing with compact spring return system (using LEONI “Bazooka” solution)

100% OLP

Different fieldbus communication supported

1/2” Air hose

Payload and range from 110-2.6 to 500-2.7

Runs completely inside robot arm and trough the wrist

8 year warranty

100% OLP

Supports both pneumatic and servo spot welding configuration with low frequency and medium frequency technologies

Includes all media required for spot welding process: cooling water, air, welding power, multibus and control signals, powerand resolver for gun servo motor

“I” variant available for seamless connections to the welding guns (trough the flange without connection) for a full integrationwith Versagun ®

Payload and range from 90-2.2 to 270-2.7

Dressing runs inside robot arm structure from base till axes 3

External dressing with compact spring return system (using LEONI “bazooka” solution)

Different fieldbus communication supported

Includes all media required for spot welding process: cooling water, air, welding power, multibus and control signals, power and resolver for gun servo motor

Payload and range from 110-2.6 to 500-2.7

Fully integrated on Spot welding functional package (mountedon robot mechanical structure, connected to control system)

6 types available according to robot configuration

No floor fixation required (type 1 and 2)

Safety managed by robot controller

Based on AEG dressing head

High efficiency chip collection system

Swing arm version for floor mounted guns available (swing arm managed by robot controlled servo motor)

MODEL DESCRIPTIONAPPLICATION

EXTERNAL DRESSING

(for Traditional Wrist Robots)

EXTERNAL DRESSING

(for Traditional Wrist Robots)

Integrated Tip Dresser

Page 27: Brochure Gamma Comau Robotics

27

Welding box

Media panel

Cabinet fully integrated with mechanical structure of base cabinet, and internally wired

MFDC and AC welding technology supported / pneumatic or servo welding gun managed

Different welding timer brands available (GFWelding, Bosch, WTC). Other brands/models can be integrated thanks to open architectures

Availability of local digital I/O to interface peripheral devices (media panel, tip dresser, etc.)

Safety device (power contactor) managed trough robot controller safety board

Welding power connection from welding box to robot base (or floor mounted guns)included in the package

Media panel unit completely integrated on Spot Welding functional package (mounted on robot controller, connected to welding box)

MFDC/AC Pneumatic and Servo spot welding configurations available

Main components: digital water flow meter, water shut-off, air pressure switch, manual valves for maintenance

Media connections from panel to robot base (or floor mounted guns) included in the package

IWCM compliant version available

Custom configurations available (e.g. BRIC version for balcony installation on Versa® lines)

Tool Changer Small thickness, low payload decrease

Robot side includes all devices required for management (I/O module, command valves, safety device) pre-wired to robot flange

Configuration available for : Material Handling, Pneumatic Spot welding and Servo Spot welding and combined applications

Air, water, power and signals connections management and different fieldbus supported (DeviceNet, Profibus, Profinet)

Tool side available for different configurations/applications

Payload: 257 kg and 500 kg

Integrated Tool Changer Seamless connection with robot loom (from robot axes 1 till tool changer flange)

No external connection, well protected and integrated with robot mechanical structure (WCM compliant)

Servo spot welding application supported with different fieldbus technology (Profibus, Profinet)

DESCRIPTIONAPPLICATION

Servo spot welding application supported with different fieldbus technology (Profibus, Profinet)

safety device) pre-wired to robot flange

Configuration available for : Material Handling, Pneumatic Spot welding and Servo Spot welding and combined applications

Air, water, power and signals connections management and different fieldbus supported (DeviceNet, Profibus, Profinet)

Tool side available for different configurations/applications

Payload: 257 kg and 500 kg

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DESCRIPTIONAPPLICATION

Robot dressing: MIG Welding Smart5 SIX: integrated robot dressing trough axes 1 to torch

Wire feeder support on robot shoulder

Collision box for torch protection

Payload: up to 6 kg

Maximum horizontal reach: 1400 mm

Repeatability: 0.05 mm

MIG Welding Power Source “Ready to weld” package including all components and accessory required toperform a MIG welding process

Different power sources available (FRONIUS, KEMPPI)

Different processes available (Pulsed, CMT)

Wide range of welding torches available (water cooling, standard or push-pull)

Integrated Robot dressing: MIG Welding SmartArc4: the new generation in arc welding application

Better performance, an innovative robot family range, more flexible

Based on Hollow Wrist technology: all dressing cables of welding torch housed inside the wrist

Collision box for torch protection

Payload: up to 5 kg

Maximum horizontal reach: 1951 mm

Repeatability: 0.05 mm

MIG Torch Different processes available (Pulsed, CMT)

Wide range of welding torches available (water cooling, standard or push-pull)

Torch cleaner Torch cleaner unit

Different types available (air, magnetic, Fronius, Binzel)

Integrated and managed by arc welding functional package

Oil spray station available

Wire cutting option available

DESCRIPTIONAPPLICATION Special FeaturesUseSizeMODEL DESCRIPTIONAPPLICATION

Torch cleaner

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DESCRIPTIONAPPLICATION

Smart SeamTrack (with welding wire) Makes it possible to maintain the welding torch on the trajectory on a joint subject tochanges in position

Multipass Multipass function allows to execute a welding beam several times in different positionand with different welding parameters. It may be used also with “search and track” functions

Variable Amplitude Joint Joint with changed amplitude

Volume and amplitude calculated functions in real time (during welding)

Smart Seam Finder (SmartSearch) Makes it possible to search a part subject to changes in position

USEPROTECTION DEGREEELECTRICAL CONNECTIONSSIZE

H x W x D(mm)

MODEL DESCRIPTIONAPPLICATION

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Arc Welding Process Monitoring The Smart Arc Monitoring software performs a real-time control of all theconditions that could interrupt the welding process and also it counts the weldingtrajectory executed. In case of anomaly it indicates the type of problem and in which seam it occurred.

Weaving Functions The weaving functions increase the width of the bead and improve the mechanicalstrength of the welding. It allows you to swing the torch to the left and to the rightperiodically and with a given angle relative to the direction of welding.

SmartVPC Function of the software SmartVPC <Vertical Position Control> is to check andcorrect the distance of a tool mounted on the robot flange by reading and processing the data received from an external sensor (or from power source directly).

Press Tending(PressToPress-Destacking)

Vacuum system on the robot for single and double vacuum pump

Integrated dressing with air pipes and signals cable

Air panel with pressure regulator and filtration

Double sheet controller and sensor for destacking robot managed through the Robot TP

Integrated Box for Cell Management

Press Automation Stamping up to 16 p/min

Management of up 255 parts with different shape & dimension

Wide range of equipment as destacker, centering, vision system, gripper, conveyor for any manufacturing requirement

Line efficiency greater than 96%

DESCRIPTIONAPPLICATION DESCRIPTIONAPPLICATION Special FeaturesUseProtection DegreeSizeMODEL DESCRIPTIONAPPLICATION

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Software Products

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SmartSpot

SmartHand SmartHand application package provides full management of end of arm tool (gripper) for material handling applications

Management of different handling grippers configured in the clamping group each one made of several inputs/outputs

Management of different part present detectors (1 part = group of sensor), with supervision feature to stop robot motion if parts drop during movements

Management of vacuum pumps and sensors

Management of automatic tool change configurations

SmartSpot application package provides a full support and management of resistance welding technological process

Different brands and models of managed welding controllers in both AC and MFDC technology, with support of adaptive weldingtechnology (if available on welding controller)

Pneumatic and servo driven gun management, with gun sw equalizing feature available as an option

Complete management of all surrounding devices required for the process as: cooling water flow meter and shut-off valve, airpressure switch, electromechanical devices within the application box

Management of integrated tip dresser for robot carried and pedestal welding guns, with “back-ground” dressing feature available as an option

Open software architecture to allow easy interface to additional devices

Automatic tool change configurations supported for both pneumatic and servo driven guns

SmartGlue SmartGlue application package provides a full support of material delivering, glueing and sealing processes

Different brands of sealing equipments managed with single and multi doser/system configurations supported

Flow modulation control syncronized with robot TCP speed

Interface to vision systems for quality inspection

C5G APPLICATIONS SOFTWARE

A wide range of application software packages able to manage the most commonly used technological processes.Each package includes a graphical user interface on the robot teach pendant to allow user input process parameters, customize process/behaviour and monitor status of process and devices.

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SmartArc SmartArc incorporates a dedicated application software whereby the operator is able to set all the welding parameters and managethe complete system from teach pendant, by means of a dedicated user interface.

The C5G SmartArc application software provides the user with the complete set of technological instructions for arc welding.Features include: possibility of programming up to 100 different welding seams for each type of workpiece, real-time control ofthe welding process, modification of welding parameters during robot movements, optimization of start, stop and re-start routines, optimization of weld seams (overlap, search, seam-track, multipass, etc.) plus a library of standard functions ready for use.

The system was designed with a view to enhancing integration and synergy between the robot and the welding unit, in order tooptimize the management of welding operations and cell efficiency.

33* Software Option

Smart Vision Interface

Several software interfaces with dedicated communication protocols available for commercial vision systems, for example ISRA,Perceptron, Oxford, Visionerf, National Instruments, GOM, Servorobot, Quiss …

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PDL2 Programming Language

It is the programming language for writing user programs and applications

It is open to handle up to 4 arms, with 10 axes each one (4 of them can be auxiliary) depending from the hardware configuration

It allows to: move robots arms, follow the program flow, send and get information over files, devices, serial protocols, monitorthe process (up to 255 events and states per program), implement error handling

It includes almost 200 predefined routines and functions with several purposes, as those to manage the arm motion and process control

It is possible to execute more than 250 multiple programs simultaneously to handle all process control aspects of an application

Controller System Software

Our multitasking system software includes: interpolation, position and velocity loops, user interface, networking and language interpretation

The internal communication is based on PowerLink and CAN for interfacing Servo Units, I/O, Fieldbus

A single controller can direct multiple robotics arms and related equipment

An integrated edit environment, including syntax check and statements execution is available on the robot controller

The controller system software also includes a various set of options in order to accomplish a possible application need

34 * Software Option

Cooperative Motion *

The cooperative motion feature simplifies the programming of applications where a workcell is composed of a robot and one ormore positioners

This is mainly useful in welding complex shapes or large workpieces

When cooperative motion is enabled, the robot position is defined with respect to the positioner so that cartesian trajectory canbe executed at constant speed while moving the workpiece

Cooperation can be enabled between a robot and its auxiliary axes or between two different arms

There is also the possibility (multi-cooperative motion) for two arms cooperating with the same group of auxiliary axesbelonging to one of the two arms

Synchronized Arms *

There is possibility of synchronizing the movement of the robot with auxiliary axes belonging to the same arm definition

It is also possible to move 2 different arms in a synchronized way; this means that all the axes start and stop at the same time

Collision Detection *

The Collision Detection algorithm allows the system to stop the robot arm motion, as soon as any noise force on joints takes effects

It allows detecting situations such as robot arm collisions with the surrounding environment, stuck tips in the welding operations,etc.

When a collision condition is detected, the system may enter into a particular status during which the robot gets compliant andemergency braking takes place

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C5G SYSTEM SOFTWARE

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35* Software Option

Conveyor Tracking *

It allows the user to write simple programs for reaching positions defined on a moving conveyor-track: the C5G Controllerautomatically compensates the instantaneous position of the conveyor

The conveyor has to be equipped with a position transducer connected to C5G Controller Unit

Cartesian Tracking (recommended for pick and place applications) - the robot is fixed and conveyor tracking is done using adynamic conveyor shifted according to the position of the track

Rail Tracking (increases the workspace of the robot allowing to work on huge parts) - the robot is mounted on a slide

Several Arms are allowed to work on the same conveyor

Up to four conveyors can be handled

Robot Absolute Accuracy *

This algorithm improves the precision of the robot positioning in the work area by offsetting the kinematic errors and the deflections caused by the weight of the mechanical parts

The model of error defined for a family of robots is parameterized for each robot

InterferenceRegions *

Interference Regions are volumes shared between robot and robot, or between robot and structures, which allow to optimise theuse of the cell inside space, in order to guarantee the collision prevention by defining the geometry of the robot working areainside volumes

Automatic Payload Identification *

An Automatic Payload Identification procedure is available to the user, allowing to obtain the required precision, in the terms ofperformance of movements, by correctly defining the payload parameters

It also allows the safeguarding of components

VP2.Builder * VP2.Builder is an application development tool which allows the programmers to create VP2 (Visual PDL2) applications using agraphical interface for setting all attributes of the objects destined to be viewed on the programming unit of the controller

Sensor Tracking *

The sensor tracking environment allows the robot to progressively move away from disposition concordantly with the requestcoming from a sensor

This is obtained keeping a deviation vector that is applied to the nominal programmed position

C5G foresees a preset of sensors integrated in the control system hardware; it also foresees external sensor which can bemounted, for example, on the tip of the tool (laser camera on the welding torch, like in ARC application, or with joint type weaving)

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VP2.Frames * VP2.Frames application program allows VP2 pages to be displayed on a PC (equipped with a Java runtime), being no longerlimited to be viewed on the C5G programming unit only

The C5G Controller, must be connected on the PC where the VP2 pages are displayed

* Software Option

WinC5G PC Program *

It is the interface, on PC, to the C5G Robot Control Unit

It is based on the TCP/IP protocol (Ethernet connection to the local network or point to point connection, remote connection viainternet, FTP server mode connection)

It allows to: directly issuing commands to the Control Unit, viewing and transferring files installed on the robot, editing andsyntax checking user’s programs, looking for occurred alarms (with related cause and remedy) and actions

It also foresees an extension available as WinC5G Full (system software option which includes, as main functionality, a dedicatedmenu for positional verification and/or conversion (e.g. linear shift, mirror) of positional values of already existing programs

Smart Sim Station

Smart Sim 3D-Lite is a powerful system for 3D simulation of Comau robotized cells

SMART Sim 3D-Lite facilitates easy simulation of robotized manufacturing cell and allows you to record the simulation in a 3D interactive movie to deliver to the customer

SMART Sim 3D-Lite is a powerful system for layout arrangement and design support

Vertical functionality allows users to optimise the positioning of the objects “Robot / Positioners / Fixtures” in vertical cell

SMART Sim 3D-Lite enables cell/line installation time reduction

SMART Sim 3D-Lite Simulation is compliant with RRS 1 specification for cycle time estimation and incorporates accuratearrangement of the manufacturing cell/line and offers total user control on the layout and simulation to optimise the virtualscenario “Robot path /Object relations”, thereby ensuring the best possible results. It generate collision-free optimised path

SMART Sim 3D-Lite is a powerful system to perform training

C5G PC SOFTWARE

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Services & Training

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Robotics Services

The satisfaction of our customers is always at the top of Comau Robotics strategy. Prompt and flexible after-sales service close to customers throughout the life cycle of their equipment. A complete range of services allows the customer to maximise the performance of Comau Robotics solution.

Help desk Commissioning Robot & PLC Programming Service Maintenance & Refurbishment Support to Production Field Modification & Retrofit Hardware & Software upgrade Service Contract Management

Service

Training at either the Comau Training Center or customer’s sites with multi-language sessions On-line support through remote diagnostics and remote aids enabled by the connection

capacity of the new robot control C5G Activities developed by experienced technicians at customer’s site, delivery of spare parts,

repairs and re-conditioning services, world-wide maintenance plans

Supply of spares/repairs for at least 10 years after product end of production

Exchange repairs & revision on price listQuotes for repair obsolete material not in price list

Maintenance & Refurbishment ContractTailored Service Contract

Spare Parts

Repairs

Service Control Sales

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Training & Educational Courses

We offer extensive and complete training courses for programmers, maintenance experts and robot operators with multi-language sessions held at Comau’s Training Center or at customer’s site by qualified skilled instructors with field experience.

Courses can be held in multi-languages, with native-language teachers or through the assistance of interpreters; complete and detailed documentation concerning course and a “certificate of attendance“ is issued upon completion of training courses.

Training courses held by field skilled teachers Training area with 4 robotized cells and dedicated rooms Training in customer language at our site or customer’s site Tailored courses on customer need Training on the job Courses from basic maintenance to advanced programming and diagnostic

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Sales +39 011 0045406 [email protected] +39 011 0045479 [email protected]

The information contained in this catalog is supplied for information only. Comau S.p.A reserves the right to alter specifications at any time without notice for technical or commercial reasons. The illustration does not necessarily show the products in their standard version. Printed in Italy by Multigrafica - 06/12 - Turin