Robotic Production Technology (RPT) introduced Robo-Lase, a new robotic laser cutting system at its technical open house at its Auburn Hills headquarters.  Automotive interior trim manufacturers witnessed this product in action, trimming a low pressure molded, textile covered interior trim product.

      RPT is the exclusive provider of this system in the United States and Canada by partnering with Robot Technology, based in Kleinostheim, Germany, the developer of this revolutionary robotic laser cutting system. Robot Technology chose RPT as its strategic partner because of RPT’s successful history in a wide variety of high accuracy, path intensive robotic trimming applications.

      “This revolutionary robotic laser cutting system brings the precision and unique cut quality of robotic laser cutting to the manufacturing factory floor of automotive interior trim suppliers, vacuum formers and paint film producers,” said Chuck Russo, CEO of Robotic Production Technology.  “It allows for trimming of some parts that cannot be processed with other trimming methods and has superior cut edge quality compared to trim presses.”

      Robot Technology has installed more than 50 of these robotic laser cutting systems at European automotive interior trim suppliers, as well as direct to the original equipment manufacturers.  Robotic Production Technology is currently installing a system in North American at a Japanese transplant.  By purchasing a Robo-Lase system in lieu of another process, the company was able to purchase one system versus two.

      The engineering ingenuity of this robotic laser cutting product makes it unique in the marketplace. The laser takes the place of the upper arm (third axis) of an articulated arm robot. This design provides the opportunity to have a custom designed wrist which has only 2 axes. This system turns a six-axis robot into a five-axis robot since the laser is taking the place of the third axis.

      The customized wrist becomes axis four and five which both feature continuous rotation due to the absence of cabling. The wrist also allows for the maximum amount of laser power to the work piece because of the minimal external optics (four) versus the external beam delivery system which has 11 or 12 external optics. With less external optics, the product is less complicated from a maintenance and reliability standpoint.

      The robotic system can incorporate a variety of sealed CO2 lasers – from 100 watts up to 500 watts while using only four external optics to get the laser beam from the resonator to the focus lens. The system includes additional technical innovations and process specific features. The well-engineered system also features Laserware, a customized software package that makes it easy to teach and incorporates safety interlocks.

      Prior to this system, the laser was external to the robot arm and the process hadn’t been used as extensively. This new design makes robotic laser trimming a more viable process from a manufacturing standpoint since it is more robust and reliable.

      This new system answers the needs of manufacturers of low pressure-molded A, B and C pillars that match the cloth of vehicle headliners.  It can be used to cut textile-based A, B and C pillars, paint films, soft trim products and other plastics and composite parts.  The clean edge quality of the laser cutting prevents fraying of materials.  The laser cutting leaves a clean, cosmetic edge and closes off the fibers of the fabric when it is used for cutting interior fabric parts.

      Since the beam delivery is through the arm of the robot rather than mounted on top of the robot, it boasts increased reliability and can maximize robot process speed.  Because of the integrated design of beam delivery, power supply and cooling lines, downtime and maintenance are also reduced. 

      RPT also introduced TrimPro, a new robot simulation software for path intensive robotic trimming. RPT featured TrimPro in a water jet cutting application cutting a mini-headliner.

      TrimPro is a PC-based offline robot simulation software which allows users to simulate and program a robot in 3-D space.  Robotic Production Technology jointly developed the product with FANUC Robotics based on its SimPRO software.  TrimPro bridges the gap for the next generation of robotic offline programming for path intensive trimming applications including water jet cutting, deflashing and router trimming for any industry.  TrimPro provides customers the tools needed to simulate and optimize the cycle times of actual work cells without the time and costs associated with a prototype setup or bringing a system down during production.  RPT has more than six seats of the software installed at current customers to date.  Additional customers are interested in purchasing the software for future systems since they see it as a significant tool. 

      “With the competitive environment, manufacturers are constantly searching for ways to trim the time it takes to get a new system up and running.  TrimPro allows our customers to create a program offline while concurrently running production,” said Russo.  “TrimPro significantly cuts the amount of time needed to finalize a robot program while in production mode.  These software tools also reduce the amount of programming while in an engineering environment, rather than on the manufacturing floor.” 

      End users can use the product to create programs off line while running production from CAD to path.  They can also use the software to create estimates and quotes including accurate cycle times for future programs since users can write programs in advance.  In addition, customers can use TrimPro as a training tool without taking a robot out of production.

      With the TrimPro software, operators bring the math data into the TrimPro work cell.  The software allows the operator to automatically create a cutting path.  Operators can program even faster by plugging a teach pendant into the laptop, a tool they already know.   TrimPro speeds up programming time by 50 percent.  Since it is a PC-based software, plugging the teach pendant into the computer gives users the opportunity to use it as an offline training tool.

      Users can import unique CAD models of parts, create a work cell including machines, part transfer devices and obstacles and teach robot paths to simulate the operation and performance of a robotic application.  Reach verification, collision detection, accurate cycle time estimates and other visual system operations are simulated in TrimPro’s unique graphical virtual environment.

      Robotic Production Technology is a turnkey robotic systems solutions provider. Industries served include aerospace, appliance, automotive, composites, construction, consumer goods, marine and plastics industries.  The company specializes in high path accurate trimming applications such as deflashing, laser cutting and scoring, router and water jet cutting.  RPT also has process expertise in material dispensing, assembly, joining, material handling and welding.  Capabilities include project management, engineering, simulation services, fabricating and machining, system integration and certification, software, training, service and support.