CONTROL & AUTOMATION EFFICIENCY & PRODUCTIVITY
WARNER ELECTRIC
Warner Electric XS & WR Series brakes reduce footprint of six-axis robot
Six-axis robots have become the standard solution for automated assembly tasks due to their ability to carry out complex manoeuvres . As they have grown in popularity , robot OEMs have strived to reduce the size and mass of their six-axis designs to promote space efficiency and productivity . When a German manufacturer of stepper motors was approached by a robot OEM to downsize its assemblies for a six-axis robot , they turned to Warner Electric to deliver highly compact X-Small ( XS ) and WR Series brakes .
Six-axis robots have become the standard solution for automated assembly tasks due to their ability to carry out complex manoeuvres .
Able to approach a work piece from any angle , six-axis robots are now a common sight on manufacturing lines . However , floorspace is still at a premium , so there is a continuing design trend towards decreasing the size and mass of robots . Reducing size improves space efficiency , allowing for the addition of more robots or other equipment on the line . Minimising mass allows for six-axis robots to enhance speed and acceleration without compromising payload – which results in increased productivity .
The end goal is a production line with a high density of robots , working within reduced space , delivering high output . Therefore , any advantage that can be gained from reducing the size and mass of components and assemblies must be seized by robot OEMs .
SPECIFYING AN OPTIMAL ROBOT BRAKE
This has been exemplified by a robot OEM , which asked its German supplier of stepper motors to assess downsizing opportunities for an updated six-axis robot design optimised for small component assembly . The German manufacturer quickly identified the brakes mounted on the back of each stepper motor as an area for optimisation . The brakes provide static holding in precise positions , ensuring the accuracy of the assembly process . Particularly , the stepper motor controlling the sixth axis of movement , which holds and turns the tooling at the end of the robot arm , required a specialised braking solution .
The manufacturer contacted Warner Electric , a leading brand of Altra Industrial Motion Corp ., due to its exceptional expertise regarding advanced braking technologies . After collaboration with the customer ’ s engineering team , Warner Electric experts recommended a XS electrically-released , spring-set brake to fit the stepper motor on the sixth axis .
Warner Electric ’ s range of XS brakes is specifically designed for applications where weight saving and space efficiency are paramount . Each model offers reliable braking to an optimised torque level . Consequently , XS brakes are often specified for applications in aeronautics and robotics . It is a highly versatile range featuring six standard sizes , with Warner Electric able to customise designs to exactly match application requirements .
The XSB33S supplied to the German motor manufacturer offered a torque rating of 35 Ncm and a weight of only 90 g . Its design ensured a significant size and mass advantage compared to the previously utilised brake . A customised adaptor flange was also included to allow for customerspecific mounting .
DELIVERING TANGIBLE IMPROVEMENT
Image Source : AdobeStock
For the higher braking torques required on the other five axes of the robot , Warner Electric supplied highly compact Model WR220 and WR225 spring-applied , electrically-released brakes . These are specifically designed as statically engaged / disengaged holding brakes , ensuring reliable positioning of the robot arm in operation .
With the new brakes now installed , the German motor manufacturer could approach the robot OEM with a highly optimised design that reduced footprint without compromising productivity . This delivered increased space efficiency for end users , improving available floorspace and enhancing production capacity .
Warner Electric provides a global design , development , manufacturing and supply service to its customers – offering standard and bespoke braking solutions tailored to specific application requirements . Experts worldwide work closely with customers ’ engineering teams to provide products that deliver tangible operational improvements . This ensures that the special requirements of advanced industries such as robotics can be met with exact solutions .
For further information , please visit www . warnerelectric-eu . com
30 PECM Issue 49