Robot Substrate Handling SystemCorrugated Board (Full Auto) (Dual Robot)

Why choose a Robot Substrate Handling System?

�� Range of Load & Unload Options

z Load1 - From a single stack to 1, 2, or 3 up on the vacuum table using the load robot.

z Unload - From the vacuum table to an uncollated stack using the unload robot.

�� Reduced Handling Time & Faster Changeover

z Robot Substrate Handling Systems reduce the overall cycle time of Onset X printers, offering users improved productivity.

z Load and unload pallets can be changed quickly, with printed sheets released to post-print finishing with minimal delay.

�� Supports a Range of Corrugated Board & Grades

z Head effectors designed and manufactured by Inca feature a number of suction cups that can be arranged in a variety of configurations, catering to a wide range of corrugated substrate sizes and flute grades.

z Distorted (bowed) substrate can be handled2 and comprehensive control of table vacuum level and zoning always ensures a flat surface for maximum print quality.

1 2 and 3 up only available with multi-pick configuration.2 Subject to limitations.

�� Reliability & Accuracy of Substrate Placement

z ABB robots have outstanding position repeatability and excellent path accuracy, permitting accurate and repeatable sheet loading on the vacuum table. This means images can be consistently printed in the same position on the substrate, making post-print finishing easier and more efficient.

�� Multiple Standard Layout Configurations with the Option to Customise

z Standard layout configurations offer a reduced footprint over traditional automation systems. If required, robot positioning and safety systems can be customised (subject to extra cost, delivery and installation time) to further maximise space utilisation.

�� Ease of Use

z Robot Substrate Handling Systems are fully integrated within the Inca GUI, making operation simple with minimal training requirements.

�� Supported by all Onset X Printers

z Robot Substrate Handling Systems are supported from the entry level Onset X1 through to the ultra-high productivity Onset X3.

Load RobotABB IRB 6700 6 Axis

Moves substrate to the printer from the load stack. The load robot

utilises its additional two axes of movement for sheet separation

during pickup.

Unload RobotABB IRB 660 4 AxisPlaces printed substrate from the printer on to the unload stack.

Load (A) and Unload (B) AreasWhen required, palletised substrate stacks are

moved in and out of the load/unload areas using a pallet truck. The position of the load and unload stacks are clearly marked. Stack

capacity (height) is subject to limitations.

Load & Unload AreaLight Curtains (shaded)When operating in Automatic and Semi-Automatic modes, entry into the load and unload areas is detected by invisible infra-red light curtains; breaking a curtain will remove power from the drives and stop printer and robot operation.

A

B

Head EffectorsEach robot is fitted with an appropriate specialised head effector, permitting reliable and effective handling of substrate types conforming to specification.

Protective Hard GuardingProtective hard guarding prevents incursion into the unload area and is installation specific. Protective hard guarding shown in this diagram assumes that the unload area is NOT adjacent to walls (hard guarding MAY NOT be required if wall(s) are present).

Controller CabinetOne or more controller cabinets may be installed (number and position dependent on robot specification).

Typical InstallationSingle Pick,

Short Edge Access

Typical Multi-Pick Load A

rea

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I © 2018 Inca Digital Printers Ltd. I

Robots1 Load Unload

Manufacturer ABB Asea Brown Boveri Ltd.

Model / # Axis IRB 6700 / 6 Axis IRB 660 / 4 Axis

Max. Height2 2.962 m (116.6 in) 2.957 m (116.4 in)

Supply 400-480 V; 3-phase and Protective Earth/Ground; 25 A per phase

Energy Consumption ISO-Cube: 2.85 kW ISO-Cube: 2.7 kW; Normal movements: 3.2 kW

1 Refer to manufacturer’s instructions for full specification including but not limited to dimensions, weight, service requirements (electrical, compressed air, etc.), environmental effects and safety systems.

2 Maximum operational height when installed to recommended specification using 500 mm plinth or base.

Inca Digital Printers Ltd. Head Effectors

Quantity 1 x Load; 1 x Unload

Suction Cups 36 per effector (12 adjustable)

Vacuum Bars 3 per effector (2 adjustable)

Smart Camera System Load effector only Ultrasonic Sensor 1 per effector

Compressed Air (per effector)

Pressure 6 bar (88 psi) Volume (at 6 bar) 1.3 m3/minute

Supply 20 mm diameter push fitting

Media & Handling - Full Automatic Operation

Supported Media Types1 Corrugated Board Flute Grades2 Micro, E, S, B, C, EB, BC

Number of Sheets3 Single Pick Configuration Single sheet load & unload

Multi-Pick Configuration Up to 3 sheets load & unload

Maximum Sheet Size Length (X): 3,220 mm (126.8 in); Width (Y): 1,600 mm (63 in)

Minimum Sheet Size Length (X): 805mm (31.7 in); Width (Y): 800 mm (31.5 in)

Gauge (Thickness)4 Minimum: 2 mm (0.078 in); Maximum 50 mm (2 in)

Maximum Weight5 10 kg (22 lb) Distortion6 25 mm (1 in) Distribution 125-300 gsm

Maximum Stack Capacity (Height)7

Load 1,300 mm (51.2 in)

Unload8 1,300 mm (51.2 in)

Table Loading Accuracy Accurate to ± 1 mm (0.039 in)

Configurations Short Edge Access Long Edge Access

Single Pick Footprint1 13.08 m x 8.12 m (514.8 in x 319.8 in) 13.08 m x 9.31 m (514.8 in x 366.6 in)

Multi-Pick Footprint1 13.08 m x 11.20 m (514.8 in x 441.1 in) 13.08 m x 12.08 m (514.8 in x 475.6 in)

Min. Ceiling Height2 3.2 m (126 in)

1 Machine + Robots + Hard Guarding; customisation may affect footprint; access space required.2 Provides necessary clearance for unimpeded robotic operation.

Safety System Components and specification are installation specific

Load & Unload Area Light Curtains1

Entry into load and unload areas is detected by invisible infra-red light curtains; breaking a curtain stops printer and robot operation

Programmable Laser Scanning System2

Configured with multiple exclusion (or safety) zones and controlled by multiple safety scanners to monitor equipment area for presence of (unprogrammed) obstacles and motion

Protective Hard Guarding Protective hard guarding prevents incursion into the load/unload areas

1 Active in Automatic and Semi-Automatic modes only.2 Incursions will stop printer when operating (robots non-operational in Manual mode).

Vacuum BarsThree vacuum bars (two of which are adjustable to provide greater support for multiple substrate sizes) are fitted on the underside of each head effector.

Ultrasonic SensorEach head effector features an ultrasonic sensor configured to

report effector height above the substrate, permitting fine

adjustment during the final moments prior to substrate

pick and placement.

Suction Cups Thirty six suction cups (fitted in pairs) are distributed equally over three vacuum bars on the underside of

each head effector and enable substrate to be loaded and unloaded reliably. Suction is created by vacuum generators operating on the Venturi effect. If a loss

of vacuum is detected on the load effector, the sheet is dropped instantly. To provide greater support for multiple substrate sizes, the position of twelve cups

can be moved along the X axis.

Smart Camera System (Load Effector Only)The load head effector features a smart digital camera system to identify and interpret the position of substrate prior to loading/unloading. Two digital cameras are mounted vertically to the underside of the effector. Camera operation is supplemented by floodlamps to ensure reliable image quality.

Inca Digital Printers Ltd. Head Effector Corrugated Board

CameraFloodlamp

While every reasonable effort has been made to ensure the accuracy and appropriateness of the content of this document, Inca Digital Printers Limited cannot be held responsible for any errors, omissions or consequential loss/damage howsoever caused. The information supplied is subject to change without notice due to on-going design improvement and a unit may differ in detail from that described.

Technical Specification

1 Check media specification and test performance before printing; effectors limited to handling corrugated board.

2 Micro and E grades should be tested to ensure repeatable sheet separation before printing.

3 Maximum number of sheets and collation ability dependent on installation layout, head effectors fitted and range of robotic movement available.

4 Maximum thickness reduced to 48 mm (1.88 in) with printed shim & table skin fitted.

5 Maximum total of all sheets distributed evenly over table; 20 kg (44 lb) maximum weight when operating in Manual mode at maximum print speed; 80 kg (176 lb) maximum weight when operating in Manual mode at reduced print speed using maximum table vacuum (speed dependent on substrate).

6 Over maximum sheet size on pallet.7 From floor; pallet + media; height installation specific and

may vary due to robot base height and effector depth.8 Solid pallet required to ensure accurate ultrasonic sensing.

Printer

LU

Single Pick - Short Edge Access

Printer

U L

Single Pick - Long Edge Access

Printer

LU

Multi-Pick - Short Edge Access

Printer

LU

Multi-Pick - Long Edge Access

L Load U Unload

Load and Unload Area Light Curtains

Protective Hard Guarding

Robot Effector

Key

I SR0259 - Robotic Substrate Handling System Datasheet (Corrugated) (Dual Robot) I Issue 4 I 5 Mar 2018 I I Inca Digital Printers Ltd I 515 Coldhams Lane, Cambridge, CB1 3JS, UK I T +44 (0)1223 577800 I E sales@incadigital.com I

A SCREEN GA Group Company