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Automation in the manufacturing sector is expanding rapidly, finding applications in a vast array of processes from assembly and inspection to packaging. Gantry systems and 6-axis industrial robots are instrumental in achieving automation in tasks such as palletizing, sorting, and pick-and-place operations.

When deciding between a gantry or a robot, it’s important to consider factors like the nature of the task, payload requirements, the type of grippers needed, as well as the distance and speeds involved.

In many scenarios, a linear motion guided gantry system can perform the same functions as an industrial robot at a lower cost and with greater adaptability. For instance, when the task involves moving heavy, awkwardly shaped items over a large area, a gantry system often proves to be the superior choice. Giles Forster, Chairman of HepcoMotion, elaborates on the advantages of gantry systems.

Expansive Working Area

A significant benefit of gantry systems is their capacity to handle heavier loads across larger distances. For example, a gantry system with a three-meter square footprint can position a 400 kg payload anywhere within that area along both axes. In contrast, industrial robots have a limited moment load capacity, which decreases as the payload extends further from the central axis.

For example, a 6-axis robot may experience a 50% reduction in payload capacity when its horizontal reach extends to just 0.7 meters. Thus, for tasks requiring movement of even modest payloads over greater distances, a larger, more expensive robot would be necessary. As the work area increases, the cost-effectiveness of gantries becomes even more apparent.

HepcoMotion has partnered with Avanti Conveyors for over 18 years, providing HDS2 gantry systems for pallet lifting. These gantries handle payloads of up to 120 kg, with speeds of 2 m/s on the X-axis and 1.8 m/s on the Z-axis, and a two-meter Z-axis stroke.

Spanning lengths from 12 to 30 meters, these systems demonstrate the suitability of gantries for large working areas. HepcoMotion offers a range of gantries tailored to different needs, from light payloads at high speeds to heavy payloads.

Handling Heavier Loads

Recently, HepcoMotion installed a rack-driven HDS2 X-Z gantry system in its factory for a multi-station chemical finishing dipping plant. This system can handle a 700 kg payload at a nominal speed of 0.5 m/s, with a long x-axis stroke of 14 meters. The system is ideal for lifting and loading four-meter-long slides into seven dipping tanks.

Two heads provide stability, making it suitable for handling these challenging shapes and sizes, which are not ideal for robots. The HDS2 system includes all mechanical elements such as legs, XZ beams, slides, bearings, rack & pinion, belt drives, and cable chains, customized to the customer’s needs.

Adaptability and Flexibility

One of the key advantages of gantry systems is their ability to adapt to changes in the work area, which can be extended even after installation. This flexibility is crucial when there is a need to increase production or accommodate changes in processes or applications. Extending a gantry’s reach is relatively simple, often requiring only one axis to be lengthened, making it a cost-effective solution.

For example, IAC Engineering, a large electrical integration and automation company, needed to extend the vertical stroke of a system. HepcoMotion provided a replacement Z-axis beam, increasing the stroke without altering the rest of the system. This flexibility contrasts with industrial robots, which often require complete replacement when an extended reach is needed.

V Guide Technology and Maintenance

For systems with heavy-duty applications covering long distances, low maintenance is crucial. HepcoMotion’s gantry systems utilize precision V guide technology, known for its unique debris expulsion mechanism, making them ideal for harsh industrial environments. The bearings in these systems can be easily removed for maintenance without taking the carriage off the axis, minimizing downtime.

In contrast, robot systems often require specialist maintenance, leading to additional costs and disruptions.

Integration and Efficient Work Envelope

Integrating new products into existing assembly lines often necessitates the inclusion of an automated gantry or robot. Gantry systems are generally simpler and more cost-effective to integrate, especially in systems driven by basic PLC controls. Unlike the complex control systems of 6-axis robots, a 3-axis gantry can often be fully integrated with existing machinery.

Moreover, gantries, which can be mounted overhead or below the work area, save valuable floor space and provide more efficient work envelopes compared to traditional industrial robots. This arrangement allows for greater access to workstations, an important factor for manufacturers aiming to minimize downtime and maximize productivity.

Conclusion

For applications that do not require the complex motion capabilities of a 6-axis robot, gantry systems offer significant advantages. They provide cost-effective, flexible, and efficient solutions, particularly for handling heavy loads across large areas.