KeMotion

Because speed counts KeMotion The automation solution for boosting robot and machine productivity

Robotics and automation in the Industry 4.0 era Contents Together for a successful automation solution 4 KeMotion – The complete solution for robot and machine automation 6 Turnkey robotics for fast project implementation 10 Intelligent look-ahead function – The basis for optimized robotics and machine processes 12 Control every machine by means of PLC and motion 16 High-performance drive technology with control and safety technology 17 2

Robotics and automation in the Industry 4.0 era In the increasingly faster moving and more highly networked world of the Industry 4.0 era, intelligent au- tomation and robotics are growing in importance. Machine and robot manufacturers are confronted with a constantly changing market and must respond with corresponding flexibility and speed. Manufacture faster and better KeMotion makes it possible to achieve maximum productivity and the fastest reaction times – even with reduced batch sizes and shorter product life cycles. Self-optimizing technology functions and an extensive simulation packet ensure the best results at an outstanding price/performance ratio. Comprehensively networked Thanks to high connectivity and the range of interfaces, the KeMotion system can easily be integrated in Industry 4.0 systems. Cloud-based diagnosis and remote services guarantee maximum system availability. Modern and flexible operation is made possible through the simple integration of smart devices. Uniqueness through open architecture The numerous customization options of the KEBA systems permit maximum individualization and differentiation through the integration of the user’s own software modules. This guarantees optimized complete solutions as well as clear market positioning and ensures success in competition. Reduce costs through ease of use All user interfaces from KEBA are well designed and offer intuitive operation and the best-possible user experi- ence. Everything works as easily and as quickly as in the consumer sector, where tablets and smart devices influence day-to-day life. Lean engineering becomes reality. Constantly new and ever-changing market demands require intelligent and flexible automation systems for robots and machines. The best solution for this is KeMotion from KEBA. Safety – Maximum safety for man and machine 18 Intuitive operation of robots and machines 20 KeMotion Packaging – The fastest robotics solution for the packaging industry 24 KeMotion Handling – The fastest robotics solution for handling applications 30 Licensing models for KeMotion / KeSafe 34 Overview KeControl 36 KeControl FlexCore – The open automation solution 38 3

The best support in every phase of a project We know the market requirements for successful automation solutions and speak the same language as our customers. The basis for this is more than 40 years of international experience on the market and profound application know-how. 100 % of development and production of all hardware and software components takes place in house at KEBA. All technologies and services for KeMotion are optimally adapted to one another. Our experienced experts offer the best-possible support during every phase of the machine life cycle. Maxi- mum customer benefits and highest productivity have top priority here. That is our understanding of long-term and successful cooperation. Together for a successful automation solution Commissioning Product development Customer project & acceptance Shortest development Optimized machines & Fastest commissioning & times & best-possible accurate offers changeovers differentiation KeMotion is based on more The specialists from KEBA Intelligent wizards and tem- than 40 years of market provide support during pro- plates simplify and speed up experience and profound ject work and sales and the processes. Furthermore, knowledge of the industry. prepare profound feasibility extensive on-site support It is a turnkey and customiz- studies. For optimization, a and comprehensive support able automation system. user-friendly 3D simulation from experts are offered. tool is available. 4

Machine operation Service & after sales Best machine performance Maximum availability & highest process quality The long-lasting systems KEBA supports its customers from KEBA are known for top with a global network of quality and very high reliabi- subsidiaries and offers 24/7 lity. KeMotion’s high-end ro- service. User-friendly logging botics technologies guarantee and diagnosis tools help maximum productivity. with process optimization. 5

KeMotion – The complete solution for robot and machine automation Robot dimensions Artarm geometry Illustration Distance base axis 1-2 in X Rotation base axis 1 Distance base axis 1-2 in Z Rotation base axis 2 Distance base axis 2-3 Distance base 3 to wrist 1 Rotation base axis 3 Rotation wrist axis 1 Rotation wrist axis 2 Distance wrist axis 2 to TCP Distance base axis 2-3 in Z Safety monitoring KeMotion stands for the fast, open and customizable automation of robots and machines in the Industry 4.0 era. Thanks to the scalable hardware in combination with many high-perfor- mance technology functions and turnkey software packages, the user can quickly and easily find the optimum solution. The all-in-one automation system PLC, motion, robotics, drive technology, safety technology and HMI are combined in a compact sys- tem with KeMotion. This is the ideal basis for implementing all automation tasks on a single common hardware and software platform. KeMotion stands for both turnkey complete solutions as well as individually adaptable systems with a variety of customization possibilities. A control for every robot More than 30 types of robots are preconfigured in the system. Furthermore, customer-specific kine- matics can be easily integrated and configured. Grinding • Metal Bending • Painting • Welding • Pick & Place • Palletizing • Handling • CNC Wafer Handling • Glueing • Service Robotics • Textile Printing • Die Casting • Plastics • etc. 6

The user-friendly multi-robot control Up to 16 robots can be efficiently operated simultaneously with one KeMotion control. A common user interface for operation and programming is available for this purpose. The multi-robot control is ideal for applications with cooperating robots and the control of entire production lines. The proven solution for a wide range of applications and processes Typical application cases for KeMotion range from machine automation to multi-robot applications. For the packaging sector and for handling applications, the special solutions KeMotion Packaging and KeMotion Handling are available with an expanded range of functions. Active Contactflange by FerRobotics © Trumpf © Dürr © IGM Grinding • Metal Bending • Painting • Welding • Pick & Place • Palletizing • Handling • CNC Wafer Handling • Glueing • Service Robotics • Textile Printing • Die Casting • Plastics • etc. 7 Options KeMotion Handling KeMotion Packaging KeMotion

Hardware and software perfectly matched KeMotion consists of five core components. At the heart of this high-performance combination is a single control system. Processes only need to be written in a single program; communication takes place directly and without delay. Numerous standardized interfaces facilitate networking with other Industry-4.0-ready devices. Configuration Robotic HMI Diagnosis Teach-in Programming environment Online programming Wizards S I/O Master SCP 3rd party I/Os Motors SCADA and/or MES system Control Supply Drives incl. safety 8

Real robotics Robotics The turnkey robotics solution from KeMotion scores with unique high-end technologies for maxi- mum performance and precision. PLC + Motion Full-fledged PLC + motion KeMotion is more than a robotics solution, it can be used to control the entire machine. Compact control and drive technology Control + Drives The modular, all-in-one KeDrive for Motion system with optionally integrated safety controller is only half as big as comparable systems. Scalable safety technology Safety KeSafe is a space-saving safety solution for PLC, single axes and robotics that guarantees maximum safety for man and machine. Intuitive operation HMI The ready-to-use robot HMI from KeMotion and the wide range of KeTop devices facilitate simple and fast operation. 9 Options KeMotion Handling KeMotion Packaging KeMotion

Implement projects more easily and faster thanks to turnkey robotics Short development times, application-optimized machine design as well as easy and fast commissioning are the funda- mental requirements of machine manufacturers. The extensive software package from KeMotion provides support with convenient features as well as intelligent wizards and templates. User-friendly tool set with more than 30 predefined types of robot For user-friendly configuration and programming of robots and ma- chines, an extensive tool set is available with KeMotion – including easy CAD import. A variety of robot types are available preconfigured in the system. After entering mechanical parameters such as dimensions, gear ratios, etc., in ready-made masks, the programming of the application already can begin. Robotic applications with up to 10x less code All robot applications are created easily and quickly with the intuitive TeachView programming system using the extensive KAIRO robot com- mand set – either online on a KeTop handheld operating device or offline on a PC. Compared to conventional systems, up to 10x less code needs to be programmed. Through the use of easy-to-understand instructions, KAIRO supports the user in programming the desired robot paths and the entire process. Simple machine optimization by means of 3D simulation The Real World Simulation Package is a user-friendly 3D simulation tool for the easy creation, optimization, validation and visualization of robot programs and machine processes. Users benefit from an Industry-4.0- compliant virtualization with numerous adjustment options for the design of machines, robots and robot cells – even before commissioning. 10

Robotics 4x faster commissioning thanks to intelligent wizards and templates Make things as easy as possible for the user – that is the meaning of the KEBA motto “parametrizing instead of programming.” Commissioning of machines and robots takes place noticeably faster; modifications can be done much more easily. Easy integration of robot tools Using a predefined program sequence, a wizard facilitates the auto- matic detection of geometries of end-of-arm tools – e.g., with grippers, welding devices, grinding devices, etc. Users do not need to program a single line of code and can fully concentrate their resources on the actual process. Freely definable working areas, blocking areas and signal areas Working, blocking and signal areas define where a robot may move and where it may not move. They serve to protect man and machine. With KeMotion, these zones are freely definable and are created step-by-step with the help of an intelligent wizard. Create palletizing patterns in just a few steps Without needing to program a single line of code, intelligent palletizing wizards guide the user to the best-possible solution for all palletizing tasks in just a few steps, for everything from the placement of a single type of product in a carton to mixed pallets. 11 Options KeMotion Handling KeMotion Packaging KeMotion

Intelligence and look-ahead function – The basis for optimized robotic and machine processes Highest economic efficiency is a must for modern production systems. The key factors here are maximum machine per- formance with minimal energy consumption. KeMotion offers numerous high-end technologies for achieving these goals. Path blending P1 Know the future Robot paths automatically planned KeMotion generates a list of movement commands on TCP basis of the robot program created with KAIRO. Every movement command corresponds to a path segment. Be- ginning with this list, the path of the robot is planned over all segments. In doing so, smooth blending movements are automatically calculated from one path segment to the next. P2 Optimized movements by means of look-ahead function While traveling the planned robot path, a so-called look-ahead function moves in advance of the actual robot by precalculating the movements of the robot for a defined period of time. KeMotion can thereby automatically cal- culate the optimum dynamics on a desired path and respond in good time. Automatic dynamic limiting Special limiter functions guarantee that the robot does not exceed the dy- namic limits at a desired speed, thereby ensuring that the motors are not overloaded. This makes possible fast, precise and, at the same time, smooth robot movements. Path planning and the look-ahead function are the basis for a wide range of technological functions, which are described in further detail on the following pages. 12

Robotics Fast and gentle on the mechanics Fast and energy-saving thanks to Intelligent Motion Without additional programming effort, Intelligent Motion automatically adapts the robot movements to other robots and processes. Based on the automatic plan- ning of the robot path, movements are optimized and abrupt start/stop actions eliminated. With high-speed pick & place applications, parts are picked up immediately upon entry into the working area and the robot is moved only as fast as necessary thanks to Intelligent Motion. This increases the performance, extends the lifetime of the mechanical parts and ensures the energy-saving use of the robot. Process control without dead time Look-ahead trigger points for maximum productivity and process quality The exact synchronization of robot movements and processes is a decisive quality factor for many robot applications. Path trigger points ensure this. Thanks to the look-ahead function, with KeMotion the dead times in the process are also com- pensated. For example, the build-up of the vacuum for a gripper starts even before the path trigger point is reached so that the vacuum is available precisely at the path trigger point. No vacuum Vacuum build- present up begins Vacuum built up Grip part Path trigger point P0 Prewarning P1 point Build-up time for vacuum Offset 13 Options KeMotion Handling KeMotion Packaging KeMotion

Unique features for more productivity and quality Robotics Collision avoidance with foresight Working and blocking areas for more safety To avoid collisions, a robot may only move within specified limits (working area) and may not move into certain areas (blocking area). With KeMotion, working areas and blocking areas can be freely defined. Thanks to the look-ahead function for the robot path, for example, exiting the working area or entering a blocking area, will be detected early and the robot will be braked automatically. If multiple robots are working together, then a common working area can be defined as well. It is thereby ensured that only one robot is active in this area at a given time. The second robot adjusts its speed so that it then enters the common working area exactly when the first robot leaves this area. 14

Traveling the ideal line Fastest movements with maximum precision thanks to the dynamic torque model The dynamic torque model is the modeled representation of the actual robot. It takes into account masses, inertias, elasticities and frictions of the individual robot components. It also compensates for mechanical fluctuations by means of elasticity compensation. In addition to the geometric properties of the robot, the physical properties are thereby also taken into account in the path interpola- tion. Not only are position, speed and acceleration calculated, the torque is determined as well. The dynamic torque model is the basis for the torque feed forward control on the drive. Taking into account the calculated torque, the path accuracy is maximized and the contouring error reduced. with torque feed forward control without torque feed forward control 15 Options KeMotion Handling KeMotion Packaging KeMotion

Control every machine with PLC and motion Robotics as well as PLC and motion are combined in a single control with KeMotion. This simplifies the system and facilitates faster commissioning. Cabling requirements are greatly reduced; interfaces between PLC, motion and robot control are eliminated. System cycle and all program sequences are always perfectly synchronized. Furthermore, us- ers benefit from a standardized programming interface and special extensions for the machine control. PLC + Motion Simple and powerful PLC programming The integrated PLC based on CODESYS 3.5 is programmable in accordance with IEC 61131-3. It supports all standardized PLC programming languages: Instruction List (IL), Structured Text (ST), Sequential Function Chart (SFC), Function Block Full-fledged machine control Diagram (FBD) and Ladder Diagram (LD). included In addition to the powerful robot control functions, the PLC and the motion function blocks, which are PLCOpen compli- ant, can also be used to control the entire machine. Standard modules, such as flying saw, cam disc and line shaft, are avail- able for this purpose. Special technology modules for the packaging industry are also already integrated, e.g., for controlling multi belts, intel- ligent infeed systems and indexing belts. 16

KeDrive for Motion – High-performance drive technology compactly combined with control and safety technology The KeDrive for Motion platform is an ideally matched combination of control, safety controller and multi-axis drives. It is highly flexible and allows optimum solutions to be found for a wide range of control and drive tasks. Control + Drives Modular, scalable system setup Cost-saving multi-axis drives Thanks to the well-designed system setup, it is also possible The highly dynamic drive modules are overload resistant to to use just individual modules of the system depending on the 300 % and are available in 1-, 2-, and 3-axis versions. automation task. For example, with a decentral control cabi- net concept, the drive modules can be used remotely from the control. Integrated safety controller The multi-axis KeSafe safety controller together with its safety I/Os can optionally be integrated directly in the control mod- A more than 50 % space saving ule. KeSafe is scalable and offers safety functions for logic, Compared to standard system configurations, the compact single axes and robotics. KeDrive for Motion system takes less than half as much space in the control cabinet. All-in-one Modular Decentral Motion control + Safety + Drives Motion Motion Drives control control + Safety 17 Options KeMotion Handling KeMotion Packaging KeMotion

KeSafe – Maximum safety for man and machine The freely programmable KeSafe safety controller makes machines and robots with serial kinematics safe. All safety-relevant standards and directives are taken into ac- count; extensive certification work is eliminated. In addition, space-saving design of the robot cells is made possible. Moreover, the integration of the safety controller in the KeDrive for Motion system results in space-savings in the control cabinet. & >1 Robotics – & Safe operation >– 1 Motion • Safe TCP speed • Safe guard speed & >1 PLC – Suitable for all kinematics • Freely selectable monitoring points on robot and tool • Including additional axes Scalable safety technology The following standards are met: KeSafe is available in 3 functional configuration levels: • Complete solution up to category 4, PLe according to • KeSafe PLC: safe logic EN ISO 13849-1 and SIL3 according to EN 62061 • KeSafe Motion: safe single axes and EN 61508 • KeSafe Robotics: safe robotics and safe • Safe single-axis functions according to EN 61800-5-2 robot axes (KeSafe Motion) • Safe robot modules according to EN ISO 10218 (KeSafe Robotics) 18

Safety Safe cooperation • Safe workspace • Safe tool orientation • Safe tool change Space-saving Smaller robot cells through intelligent safety functions KeSafe guarantees the safe monitoring of the robot working areas, the speed at the TCP and freely definable robot points. Uncontrolled robot movements are reliably prevented. Safety guards for safe enclosure can be mounted closer to the ro- bot, which makes possible space-saving cells with minimal footprint. 19 Options KeMotion Handling KeMotion Packaging KeMotion

KeTop – Intuitive operation of robot and machine Best ergonomics and an intuitive user interface are key factors for efficient operation and monitoring. With the KeTop devices, high-performance, application-optimized hardware is available. The turnkey TeachView robotics user interface enables fast and easy teach-in. User-friendly HMIs are created with the easy-to-operate KeView visualization software; an optimum user experience is guaranteed. The sophisticated operating concept for working efficiently with robots The turnkey TeachView robotics user interface enables the time-saving creation of robot programs. In do- ing so, the user can make use of the extensive KAIRO robot command set as well as numerous intelligent wizards and templates. This guarantees optimum results in record time. Moreover, various KeTop handheld operating devices for intuitive teach-in are available. Modern features, such as gyro sensors for easy pointing the desired direction of robot movements, additional rear side key- boards for simultaneously moving multiple axes and targeted user guidance – such as by displaying and hiding buttons – results in an optimized complete package for user-friendly and error-free robot program- ming. Versatile customization possibilities for hardware and software Perfect integration of the KeTop operating devices in existing customer solutions is easily possible thanks to extensive customization possibilities with respect to housing construction, operating elements, keyboard layout and machine visualization. 20