Brochure Gamma Comau Robotics

E
N
Your Robotized Solution
INDEX
3 Company Overview
6 Robots: General Purpose
12 Robots: Hollow Wrist
16 Robots: PAL - Press - SmartLaser
18 Positioners - Slides - Motors
21 Control Unit - Teach Pendant
24 Athomo Cell & Applications
31 Software Products
37 Services & Training
Comau Robotics
Comau Robotics, as a top global manufacturer of high quality industrial robots, offers a broad range
of technologically advanced robotized solutions designed to maximize customers productivity in
response to challenging market demands.
A partnership with Comau means increased efficiency and productivity.
Our innovative technology, integrated solutions, turn-key systems and robotized cells, supported by
highly qualified systems integrators, can help businesses in the automotive industry, among others,
to be more competitive in todays increasingly fast-paced markets.
SMART Robots
Comau Robotics offers a wide range of innovative robot models, six and multi-axes articulated
robots, covering all payload categories and applications. Technologically advanced, reliable, flexible,
and specifically tailored to our customers goals, our SMART robotized solutions guarantee optimal
performance in several industrial sectors.
Comau Robotics features a broad selection of robot families, small, medium and high payload,
robotized cells and process-integrated solutions.
3
Small/Medium payload (up to 60 kg)
SMART SIX, NS, NM and New NJ 60 - SMART5 Arc4
With payload from 5 kg to 60 kg, these models are typically used for arc-welding, machine tool
tending, assembly, manipulating, sealing and polishing. One of the main features is high repeatability
(up to 0.05 mm), suiting all applications where high speed and precision are required.
SMART5 Arc4: an innovative robot family range in arc welding application, based on hollow wrist
technology, with all dressing cables of the welding torch housed inside the wrist.
Robot Range
High payload (up to 270 kg)
SMART5 NJ Family: with a payload from 90 kg to 270 kg, these models represent the state of art
in mechanical dressing, offering top performances in terms of lightness, speed, robustness and
precision. All these models can be mounted in floor or ceiling position. Robots from this family
range are available both in the standard wrist version (NJ models) and in the hollow wrist
version (NJ4 Models). The innovative, yet long established, hollow wrist technology has been
further enhanced in the SMART5 NJ4 models: the entire welding dressing is housed in the forearm,
rather than externally as in conventional robots. This solution guarantees an unequalled level
of performance and saving in maintenance costs, allowing 100% off-line robot programming.
Recently introduced to the market, new SMART5 PAL is the Comau robot specifically designed for all
palletizing applications (payload 180 kg and 260 kg).
Heavy Duty Payload (up to 800 kg)
Within SMART5 NJ family range, we have models for heavy-duty applications, with payload from
290 kg to 500 kg. SMART5 NJ heavy-duty models have the best-in-class ratio between max payload,
up to 500 kg, and reach, 3.0 m, with a floor space-saving base. Thanks to their specific features, these
robots can operate over a wide working area and can be used for several applications: handling and
machining in foundry industry, spot welding, polishing, grinding, deburring, heavy-duty palletizing
and pick up operations.
SMART NX family: the strongest model in Comau family range.
Robotized Cells
Comau Robotics offer includes high-quality standard robotized solutions, such as the Athomo arc
welding cell.
Plus, in keeping with the Comau name, we guarantee prompt and flexible after-sale service.
Our highly qualified and skilled team guide and assist customers, whether it be for immediate
intervention or for long-term scheduled maintenance.
4
NJ4 Robot Family
The effective solution for Spot Welding
Symmetrical Structure
The solution applied to the NJ4 series
have privileged the perfect symmetry
of the mechanical structure. There are
two big advantages: specularity of the
two sides of the welding line and a
considerable time reduction in off-line
simulation and programming.
Integrated Dressing
Comau has launched a new challenge in
spot welding applications: the creation
of a hollow machine containing a
completely integrated dressing, so that
the actual mechanical overall dimensions
are never increased by external cables.
Power
Saving
The manufacturing features of the new
NJ4 (agile and light structure, reduced
weight) allow high performance and
important energy saving, up to 25%
more than the other similar robots.
Year
Full Warranty
The new Comau Robotics technology
of the integrated dressing provides
certainty of long duration, reduction
of break-downs and savings in terms
of cost for service cable replacement.
That is why Comau Robotics guarantees
the integrated dressing for 8 years of
continuous work, on 3 shifts, 365 days
per year.
5
Robots: General Purpose
6
AVAILABLE
VERSIONS
PROTECTION
DEGREE
ASSEMBLY
POSITION
WEIGHT
(kg)
REACH
(mm)
RP
(mm)
LOAD
(kg)
AXES MODEL
IP65
Floor
Ceiling
Tilted
(max 45)
160 1400 0.05 6 6
Arc Welding
Handling / Packaging
Arc
Applications
Smart5 SiX 6-1.4
RP =Repeatability ISO 9283
Arc Welding
Assembly
Plasma Cutting / Water Jet
Polishing / Deburring
7
Arc Welding
Assembly
IP65 / IP67
Wrist
Floor
Ceiling
Tilted
(max 45)
335 1650 0.05 16 6
Hand / Arc
Foundry
Applications
Smart5 NS 16-1.65
Arc Welding
Assembly
Cosmetic Sealing
Laser Welding
Laser Cutting
IP65 / IP67
Wrist
Floor
Ceiling
Tilted
(max 45)
715 3100 0.01 16 6
Hand / Arc
Foundry
Applications
Smart5 NM 16-3.1 In-Line
S c a l a 1 : 3 0
S M A R T - 5 N S - 1 2 - 1 . 8 5 H a n d
S c a l a 1 : 3 0
S M A R T - 5 N S - 1 6 - 1 . 6 5 H a n d
S c a l a 1 : 3 0
S M A R T - 5 N M 1 6 - 3 . 1 H A N D
S c a l a 1 : 3 0
S M A R T - 5 N M 2 5 - 2 . 2 ( I n - l i n e )
S c a l a 1 : 3 0
S M A R T - 5 S i X 6 - 1 . 4
IP65 / IP67
Wrist
Floor
Ceiling
Tilted
(max 45)
335 1850 0.05 12 6
Hand / Arc
Foundry
Applications
Smart5 NS 12-1.85
Arc Welding
Assembly
Cosmetic Sealing
Laser Welding
Laser Cutting
Machine Tending Machine T Machine T
Measuring Testing Measuring T Measuring T
IP65 / IP67
Wrist
Floor
Ceiling
Tilted
(max 45)
685 2241 0.06 25 6
Arc
Foundry
Applications
Smart5 NM 25-2.2 In-Line
AVAILABLE
VERSIONS
PROTECTION
DEGREE
ASSEMBLY
POSITION
WEIGHT
(kg)
REACH
(mm)
RP
(mm)
LOAD
(kg)
AXES MODEL
IP65 / IP67
Wrist
Floor
Ceiling
Tilted
(max 45)
685 2241 0.06 25 6
Arc Welding
Assembly
Cosmetic Sealing
Foundry
Laser Welding
Arc
Foundry
Applications
Smart5 NM 25-2.2 Off-set
IP65 / IP67
Wrist
Floor
Ceiling
Tilted
(max 45)
680 2000 0.06 45 6
Arc
Foundry
Applications
Smart5 NM 45-2.0 Off-set
IP65 / IP67
Wrist
Floor
Ceiling
Tilted
(max 45)
550 2258 0.06 60 6 -
Applications
Smart5 NJ 60-2.2
IP65 / IP67
Wrist
Floor
Ceiling
Tilted
(max 45)
680 2000 0.06 45 6
Arc
Foundry
Wash
Applications
Smart5 NM 45-2.0 In-line
IP65 / IP67
Wrist
Floor
Ceiling
1070 2980 0.07 110 6 Foundry
Applications
Smart5 NJ 110-3.0
Laser Cutting
Arc Welding
Assembly
Cosmetic Sealing
Foundry
Laser Welding
Laser Cutting
Arc Welding
Assembly
Cosmetic Sealing
Foundry
Laser Welding
Laser Cutting
Assembly
Cosmetic Sealing
Dispensing
Foundry
Laser Welding
Laser Cutting
Press to Press
Processing Machining
Wood / Glass Machine
Assembly
Cosmetic Sealing
Dispensing
Foundry
Laser Welding
Laser Cutting
Spot Welding
8
S c a l a 1 : 3 0
S M A R T - 5 N M 2 5 - 2 . 2 ( I n - l i n e )
S c a l a 1 : 3 0
S M A R T - 5 N M 4 5 - 2 . 0 ( I n - l i n e )
S c a l a 1 : 3 0
S M A R T - 5 N M 4 5 - 2 . 0 ( I n - l i n e )
S c a l a 1 : 3 0
S M A R T - 5 N J - 6 0 - 2 . 2
S c a l a 1 : 3 0
S M A R T - 5 N J - 1 1 0 - 3 . 0
AVAILABLE
VERSIONS
PROTECTION
DEGREE
ASSEMBLY
POSITION
WEIGHT
(kg)
REACH
(mm)
RP
(mm)
LOAD
(kg)
AXES MODEL
IP65 / IP67
Wrist
Floor
Ceiling
1050 2616 0.07 130 6 Foundry
Applications
Smart5 NJ 130-2.6
Spot Welding
Assembly
Foundry
9
Spot Welding
Assembly
Foundry
IP65 / IP67
Wrist
Floor
Ceiling
1220 2701 0.075 220 6 Foundry
Applications
Smart5 NJ 220-2.7
Spot Welding
Assembly
Foundry
Palletizing
IP65 / IP67
Wrist
Floor
On Platform
1430 3450 0.1 165 6 Foundry
Applications
Smart5 NJ 165-3.4 SH
IP65 / IP67
Wrist
Floor
Ceiling
1240 3000 0.085 165 6 Foundry
Applications
Smart5 NJ 165-3.0
Spot Welding
Assembly
Foundry
IP65 / IP67
Wrist
Floor
On Platform
1415 3151 0.1 210 6 Foundry
Applications
Smart5 NJ 210-3.1 SH
Assembly
Cosmetic Sealing
Dispensing
Foundry
Spot Welding
S c a l a 1 : 3 0
S M A R T - 5 N J - 1 3 0 - 2 . 6
3
S c a l a 1 : 3 0
S M A R T - 5 N J 1 6 5 - 3 . 0
S c a l a 1 : 3 0
S M A R T - 5 N J 2 2 0 - 2 . 7
S c a l a 1 : 3 0
S M A R T - 5 N J 1 6 5 - 3 . 4 S H
S c a l a 1 : 3 0
S M A R T - 5 N J 2 1 0 - 3 . 1 S H
AVAILABLE
VERSIONS
PROTECTION
DEGREE
ASSEMBLY
POSITION
WEIGHT
(kg)
REACH
(mm)
RP
(mm)
LOAD
(kg)
AXES MODEL
IP65 / IP67
Wrist
Floor 2150 2997 0.15 290 6
Spot Welding
Assembly
Foundry
Foundry
Applications
Smart5 NJ 290-3.0
IP65 / IP67
Wrist
Floor 2450 2997 0.15 370 6 Foundry
Applications
Smart5 NJ 370-3.0
IP65 / IP67
Wrist
Floor 2450 2997 0.15 420 6 -
Applications
Smart5 NJ 420-3.0
IP65 / IP67
Wrist
Floor 2100 2703 0.15 370 6 Foundry
Applications
Smart5 NJ 370-2.7
IP65 / IP67
Wrist
Floor 2400 2703 0.15 450 6 Foundry
Applications
Smart5 NJ 450-2.7
Spot Welding
Assembly
Foundry
Spot Welding
Assembly
Foundry
Spot Welding
Assembly
Foundry
Assembly
Cosmetic Sealing
Dispensing
Foundry
Laser Welding
Laser Cutting
10
S c a l a 1 : 3 0
S M A R T - 5 N J - 2 9 0 - 3 . 0
S c a l a 1 : 3 0
S M A R T - 5 N J - 3 7 0 - 2 . 7
S c a l a 1 : 3 0
S M A R T - 5 N J - 3 7 0 - 3 . 0
S c a l a 1 : 3 0
S M A R T - 5 N J - 4 2 0 - 3 . 0
S c a l a 1 : 3 0
S M A R T - 5 N J - 4 5 0 - 2 . 7
AVAILABLE
VERSIONS
PROTECTION
DEGREE
ASSEMBLY
POSITION
WEIGHT
(kg)
REACH
(mm)
RP
(mm)
LOAD
(kg)
AXES MODEL
IP65 / IP67
Wrist
Floor 2400 2703 0.15 500 6 -
Applications
Smart5 NJ 500-2.7
Assembly
Foundry
11
Assembly
Foundry
IP65 / IP67
Wrist
Floor 5900 3815 0.2 800 4 -
Applications
Smart5 NX 800-3.8 4A
IP65 / IP67
Wrist
Floor 6000 3036 0.2 600 6 -
Applications
Smart5 NX 600-3.0
Spot Welding
Assembly
S c a l a 1 : 3 0
S M A R T - 5 N J - 5 0 0 - 2 . 7
S c a l a 1 : 3 0
S M A R T N X 1 - 6 0 0 ( 6 A x . )
S c a l a 1 : 3 0
S M A R T N X 1 - 8 0 0 ( 4 A x . )
Robots: Hollow Wrist
12
S c a l a 1 : 3 0
S M A R T - 5 A r c 4
S c a l a 1 : 3 0
S M A R T - 5 N J 4 - 9 0 - 2 . 2
S c a l a 1 : 3 0
S M A R T - 5 N J 4 - 1 7 0 - 2 . 5
S c a l a 1 : 3 0
S M A R T - 5 N J 4 - 9 0 - 2 . 2
S c a l a 1 : 3 0
S M A R T - 5 N J 4 - 1 7 0 - 2 . 9
AVAILABLE
VERSIONS
PROTECTION
DEGREE
ASSEMBLY
POSITION
WEIGHT
(kg)
REACH
(mm)
RP
(mm)
LOAD
(kg)
AXES MODEL
IP65
Floor
Ceiling
Tilted
375 1951 0.05 5 6
Arc Welding
Assembly
Arc
Applications
Smart5 ARC4
Spot Welding
Handling
13
Spot Welding
Handling
IP65
Floor
Ceiling
698 2210 0.07 110 6 I* / TC**
Applications
Smart5 NJ4 110-2.2
Spot Welding
Handling
IP65
Floor
Ceiling
1100 2500 0.1 170 6 I* / TC**
Applications
Smart5 NJ4 170-2.5
IP65
Floor
Ceiling
698 2210 0.07 90 6 I* / TC**
Applications
Smart5 NJ4 90-2.2
Spot Welding
Handling
IP65
Floor
Ceiling
1240 2918 0.1 170 6 I* / TC**
Applications
Smart5 NJ4 170-2.9
* Integrated spot welding gun
** Integrated tool change
S c a l a 1 : 3 0
S M A R T - 5 N J 4 - 2 2 0 - 2 . 7
AVAILABLE
VERSIONS
PROTECTION
DEGREE
ASSEMBLY
POSITION
WEIGHT
(kg)
REACH
(mm)
RP
(mm)
LOAD
(kg)
AXES MODEL
IP65
Floor
Ceiling
1080 2204 0.1 175 6
Spot Welding
Handling
I* / TC**
Applications
Smart5 NJ4 175-2.2
IP65
Floor
On Platform
1470 3188 0.1 210 6 I* / TC**
Applications
Smart5 NJ4 210-3.1 SH
IP65
Floor
Ceiling
1260 2417 0.15 220 6 I* / TC**
Applications
Smart5 NJ4 220-2.4
IP65
Floor
On Platform
1420 3377 0.1 165 6 I* / TC**
Applications
Smart5 NJ4 165-3.4 SH
IP65
Floor
Ceiling
1290 2734 0.15 220 6 I* / TC**
Applications
Smart5 NJ4 220-2.7
Spot Welding
Handling
Spot Welding
Handling
Spot Welding
Handling
Spot Welding
Handling
14
S c a l a 1 : 3 0
S M A R T - 5 N J 4 - 1 6 5 - 3 . 4 S H
S c a l a 1 : 3 0
S M A R T - 5 N J 4 - 1 7 5 - 2 . 2
S c a l a 1 : 3 0
S M A R T - 5 N J 4 - 2 1 0 - 3 . 1 S H
S c a l a 1 : 3 0
S M A R T - 5 N J 4 - 2 2 0 - 2 . 4
AVAILABLE
VERSIONS
PROTECTION
DEGREE
ASSEMBLY
POSITION
WEIGHT
(kg)
REACH
(mm)
RP
(mm)
LOAD
(kg)
AXES MODEL
IP65 Floor 2005 3002 0.15 220 6 I* / TC**
Applications
Smart5 NJ4 220-3.0
Spot Welding
Handling
15
IP65 Floor 1975 2703 0.15 270 6 I* / TC**
Applications
Smart5 NJ4 270-2.7
Spot Welding
Handling
S c a l a 1 : 3 0
S M A R T - 5 N J 4 - 2 2 0 - 3 . 0
S c a l a 1 : 3 0
S M A R T - 5 N J 4 - 2 7 0 - 2 . 7
Robots: PAL - Press - SmartLaser
16
S c a l a 1 : 3 0
S M A R T - 5 N J L A S E R
AVAILABLE
VERSIONS
PROTECTION
DEGREE
ASSEMBLY
POSITION
WEIGHT
(kg)
REACH
(mm)
RP
(mm)
LOAD
(kg)
AXES MODEL
IP65 Floor 1250 3100 0.15 180 4
Palletizing
-
Applications
Smart5 PAL 180-3.1
Palletizing
17
Press to Press
IP65 Floor 2250 3100 0.2 470 4 -
Applications
Smart5 PAL 470-3.1
Press to Press
IP65 Floor 1270 3209 0.17 100 6 -
Applications
Smart5 NJ Press 100-3.2
IP65 Floor 1250 3100 0.15 260 4 -
Applications
Smart5 PAL 260-3.1
Laser Cutting
Laser Welding
IP65 Floor 1150 3100 0.07 - 7 -
Applications
Smart5Laser
Press to Press
IP65
Floor
On Platform
1515 3700 0.2 130 6 -
Applications
Smart5 NJ Press 130-3.7 SH
S c a l a 1 : 3 0
S M A R T - 5 P A L 1 8 0 - 3 . 1
S c a l a 1 : 3 0
S M A R T - 5 P A L 2 6 0 - 3 . 1
S c a l a 1 : 3 0
S M A R T - 5 P A L 4 7 0 - 3 . 1
S c a l a 1 : 3 0
S M A R T - 5 P R E S S - N J 1 0 0 - 3 . 2
S c a l a 1 : 3 0
S M A R T - 5 N J 1 6 5 - 3 . 4 S H
Positioners - Slides - Motors
18
19
19
VERSION MAX PAYLOAD
(kg)
MAX DIAMETER
(mm)
MAX LENGTH
(mm)
250 1.1-1.6 2x250 1100 1600
500 1.2-2.0 2x500 1200 2000
500 1.2-2.5 2x500 1200 2500
750 1.2-2.0 2x750 1200 2000
850 1.2-2.5 2x850 1200 2500
Smart5 PTDV
INFORMATION
MODEL
VERSION MAX PAYLOAD
(kg)
MAX DIAMETER
(mm)
MAX LENGTH
(mm)
500 1.2-2.0 2x500 1200 2000
500 1.2-2.5 2x500 1200 2500
500 1.2-3.0 2x500 1200 3000
500 1.2-3.5 2x500 1200 3500
500 1.2-4.0 2x500 1200 4000
VERSION MAX PAYLOAD
(kg)
MAX DIAMETER
(mm)
MAX LENGTH
(mm)
250 2x250 1100 1000
Smart5 PTDO
750 1.2-2.0 2x750 1200 2000
750 1.2-2.5 2x750 1200 2500
750 1.2-3.1 2x750 1200 3100
750 1.2-3.5 2x750 1200 3500
750 1.2-4.0 2x750 1200 4000
750 1.2-5.0 2x750 1200 5000
VERSION MAX PAYLOAD
(kg)
MAX DIAMETER
(mm)
MAX LENGTH
(mm)
1000 1000 1100 800
Smart5 PTSORB
20
Slide C5G VERSION ROBOT SPEED
(m/s)
TRAVEL LENGHT
(m)
TM-52 NS 1.6 2 30
TM-72 NM - NJ LIGHT 1.6 2 30
TM-90 NJ HEAVY 1.6 2 30
Motors MODEL NOMINAL SPEED
(rpm)
NOMINAL SPEED TORQUE
(nm)
Motor 0.35 nm - C5G - IP67 5000 0.31
Motor 0.75 nm - C5G - IP65/67 4500 0.56
Motor 3.5 nm - C5G - IP65/67 4500 2.7
Motor 5 nm - C5G - IP65/67 4500 3.75
Motor 9 nm - C5G - IP65/67 4000 6.2
Motor 13 nm - C5G - IP65/67 4000 9
Motor 18 nm - C5G - IP65/67 4200 12.5
Motor 25 nm - C5G - IP65/67 3700 17.5
Motor 33 nm - C5G - IP65/67 3550 23
Motor 33 nm - C5G - IP44 -FAN 3550 23
VERSION MAX PAYLOAD
(kg)
OUTPUT ROTATION
SPEED (/s)
RP AT 500 mm
(mm)
1000 1000 69 0.1
3000 3000 50 0.1
4500 4500 52 0.15
6000 6500 35 0.2
VERSION MAX PAYLOAD
(kg)
OUTPUT ROTATION
SPEED (/s)
RP AT 500 mm
(mm)
500 500 150 0.05
1000 1000 150 0.06
1250 1250 150 0.06
2500 2500 100 0.09
5000 5000 27 0.10
Smart5 MP
Smart5 TR
MODEL INFORMATION
21
Control Unit - Teach Pendant
22
1100 x 800 x 500
400V to 500V
50/60Hz
IP54
( IP2 x rear side )
All Robots
1100 x 800 x 500
400V to 500V
50/60Hz
IP54
( IP2 x rear side )
Two Robots
SIX or NS
Plus a Rotary Table
1700 x 800 x 500
400V to 500V
50/60Hz
IP54
( IP2 x rear side )
Two Robots
SIX or NS
Plus Three or Five
Axes Positioners
540 x 800 x 500 - IP54
For cell management
modules integration
Special Features Use Protection Degree Size MODEL
C5G - Robot Controller
C5G - TWIN Controller
(multirobot management)
C5G - Power Controller
USE PROTECTION DEGREE ELECTRICAL CONNECTIONS
SIZE
H x W x D
(mm)
MODEL
C5G - Empty Box
23
- - For all C5G control cabinet -
Screen: 6.4
Weight: 1.47 kg
IP54 For all robots Selector key function
Screen: 6.4
Weight: 1.09 kg
IP54 For all robots Selector key function
SIZE
H x W x D
(mm)
MODEL SPECIAL FEATURES USE PROTECTION DEGREE SIZE MODEL
C5G Weels Kit
C5G - Teach Pendant Wireless
C5G - Teach Pendant Wired
Athomo Cell & Applications
24
25
2 SMART5 ARC4 hollow wrist robots with integrated arc welding dressing
2 Fronius TransPulse Synergic 4000 power source
SMART5 PTDV 750-2.0 double lathe positioner with vertical station changer:
Payload per station: 750 kg
Distance between plates: 2000 mm
Rotating diameter: 1200 mm
A single C5G control unit for simultaneous, integrated control of 2 robots and positioner (15 controlled axes)
Fast fixture change
Rotary distributors for water, air and current fieldbus signal (PROFINET)
Integrated PLC to control cell, safety devices and fixtures
Siemens operator interface with 10 colour touchscreen
Perimeter safety protection
Single integrated power (380 Vac) and fluidic (air) interface
Manual load/unload area protected by certified light barrier and laser scanner
Rigid and fork-liftable cell supporting and joining frame for transport by conventional vehicles, with no need for disassembly
Maximum dimensions: 5700 mm x 4150 mm
SPECIAL VERSIONS AND OPTIONS
The Athomo cell is also available in versions with:
SMART5 PTDV 850-2.5 positioner (station payload 850 kg and distance between plates 2500 mm)
Fronius TS 4000, TS/TPS 5000 or CMT 4000 power sources
Plug & Play Cell for Arc Welding
26
DESCRIPTION APPLICATION
Robot Dressing - Material Handling
INTEGRATED DRESSING
(for Hollow Wrist Robots)
EXTERNAL DRESSING
(for Traditional Wrist Robots)
Robot Dressing: Spot Welding
INTEGRATED DRESSING
(for Hollow Wrist Robots)
EXTERNAL DRESSING
(for Traditional Wrist Robots)
Runs completely inside robot arm and trough the wrist
8 Year warranty
100% OLP
Different fieldbus communication supported
1/2 air hose
Payload and range from 90-2.2 to 270-2.7
Dressing runs inside robot arm structure from base till axes 3
External dressing with compact spring return system (using
LEONI Bazooka solution)
100% OLP
1/2 Air hose
Runs completely inside robot arm and trough the wrist
8 year warranty
100% OLP
Supports both pneumatic and servo spot welding configuration
with low frequency and medium frequency technologies
Includes all media required for spot welding process: cooling
water, air, welding power, multibus and control signals, powerand
resolver for gun servo motor
I variant available for seamless connections to the welding
guns (trough the flange without connection) for a full integration
with Versagun
Dressing runs inside robot arm structure from base till axes 3
External dressing with compact spring return system (using
LEONI bazooka solution)
Includes all media required for spot welding process: cooling
water, air, welding power, multibus and control signals, power
and resolver for gun servo motor
Fully integrated on Spot welding functional package (mounted
on robot mechanical structure, connected to control system)
6 types available according to robot configuration
No floor fixation required (type 1 and 2)
Safety managed by robot controller
Based on AEG dressing head
High efficiency chip collection system
Swing arm version for floor mounted guns available (swing arm
managed by robot controlled servo motor)
MODEL DESCRIPTION APPLICATION
27
Welding box
Media panel
Cabinet fully integrated with mechanical structure of base cabinet, and internally wired
MFDC and AC welding technology supported / pneumatic or servo welding gun managed
Different welding timer brands available (GFWelding, Bosch, WTC). Other brands/models
can be integrated thanks to open architectures
Availability of local digital I/O to interface peripheral devices (media panel, tip dresser, etc.)
Safety device (power contactor) managed trough robot controller safety board
Welding power connection from welding box to robot base (or floor mounted guns)
included in the package
Media panel unit completely integrated on Spot Welding functional package (mounted on
robot controller, connected to welding box)
MFDC/AC Pneumatic and Servo spot welding configurations available
Main components: digital water flow meter, water shut-off, air pressure switch, manual
valves for maintenance
Media connections from panel to robot base (or floor mounted guns) included in the
package
IWCM compliant version available
Custom configurations available (e.g. BRIC version for balcony installation on Versa lines)
Tool Changer Small thickness, low payload decrease
Robot side includes all devices required for management (I/O module, command valves,
safety device) pre-wired to robot flange
Configuration available for : Material Handling, Pneumatic Spot welding and Servo Spot
welding and combined applications
Air, water, power and signals connections management and different fieldbus supported
(DeviceNet, Profibus, Profinet)
Tool side available for different configurations/applications
Payload: 257 kg and 500 kg
Integrated Tool Changer Seamless connection with robot loom (from robot axes 1 till tool changer flange)
No external connection, well protected and integrated with robot mechanical structure
(WCM compliant)
Servo spot welding application supported with different fieldbus technology (Profibus,
Profinet)
DESCRIPTION
APPLICATION
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Robot dressing: MIG Welding Smart5 SIX: integrated robot dressing trough axes 1 to torch
Wire feeder support on robot shoulder
Collision box for torch protection
Payload: up to 6 kg
Maximum horizontal reach: 1400 mm
Repeatability: 0.05 mm
MIG Welding Power Source
Ready to weld package including all components and accessory required to
perform a MIG welding process
Different power sources available (FRONIUS, KEMPPI)
Different processes available (Pulsed, CMT)
Wide range of welding torches available (water cooling, standard or push-pull)
Integrated Robot dressing: MIG Welding SmartArc4: the new generation in arc welding application
Better performance, an innovative robot family range, more flexible
Based on Hollow Wrist technology: all dressing cables of welding torch housed inside
the wrist
Collision box for torch protection
Payload: up to 5 kg
Maximum horizontal reach: 1951 mm
Repeatability: 0.05 mm
MIG Torch Different processes available (Pulsed, CMT)
Wide range of welding torches available (water cooling, standard or push-pull)
Torch cleaner Torch cleaner unit
Different types available (air, magnetic, Fronius, Binzel)
Integrated and managed by arc welding functional package
Oil spray station available
Wire cutting option available
Special Features Use Size MODEL DESCRIPTION APPLICATION
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DESCRIPTION
APPLICATION
Smart SeamTrack (with welding wire) Makes it possible to maintain the welding torch on the trajectory on a joint subject to
changes in position
Multipass Multipass function allows to execute a welding beam several times in different position
and with different welding parameters. It may be used also with search and track
functions
Variable Amplitude Joint Joint with changed amplitude
Volume and amplitude calculated functions in real time (during welding)
Smart Seam Finder (SmartSearch) Makes it possible to search a part subject to changes in position
SIZE
H x W x D
(mm)
MODEL
DESCRIPTION
APPLICATION
30
Arc Welding Process Monitoring The Smart Arc Monitoring software performs a real-time control of all the
conditions that could interrupt the welding process and also it counts the welding
trajectory executed. In case of anomaly it indicates the type of problem and in
which seam it occurred.
Weaving Functions The weaving functions increase the width of the bead and improve the mechanical
strength of the welding. It allows you to swing the torch to the left and to the right
periodically and with a given angle relative to the direction of welding.
SmartVPC Function of the software SmartVPC <Vertical Position Control> is to check and
correct the distance of a tool mounted on the robot flange by reading and processing
the data received from an external sensor (or from power source directly).
Press Tending
(PressToPress-Destacking)
Vacuum system on the robot for single and double vacuum pump
Integrated dressing with air pipes and signals cable
Air panel with pressure regulator and filtration
Double sheet controller and sensor for destacking robot managed through the Robot TP
Integrated Box for Cell Management
Press Automation Stamping up to 16 p/min
Management of up 255 parts with different shape & dimension
Wide range of equipment as destacker, centering, vision system, gripper, conveyor for
any manufacturing requirement
Line efficiency greater than 96%
DESCRIPTION APPLICATION DESCRIPTION APPLICATION
Special Features Use Protection Degree Size MODEL DESCRIPTION APPLICATION
Software Products
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32
SmartSpot
SmartHand SmartHand application package provides full management of end of arm tool (gripper) for material handling applications
Management of different handling grippers configured in the clamping group each one made of several inputs/outputs
Management of different part present detectors (1 part = group of sensor), with supervision feature to stop robot motion if parts
drop during movements
Management of vacuum pumps and sensors
Management of automatic tool change configurations
SmartSpot application package provides a full support and management of resistance welding technological process
Different brands and models of managed welding controllers in both AC and MFDC technology, with support of adaptive welding
technology (if available on welding controller)
Pneumatic and servo driven gun management, with gun sw equalizing feature available as an option
Complete management of all surrounding devices required for the process as: cooling water flow meter and shut-off valve, air
pressure switch, electromechanical devices within the application box
Management of integrated tip dresser for robot carried and pedestal welding guns, with back-ground dressing feature available
as an option
Open software architecture to allow easy interface to additional devices
Automatic tool change configurations supported for both pneumatic and servo driven guns
SmartGlue
SmartGlue application package provides a full support of material delivering, glueing and sealing processes
Different brands of sealing equipments managed with single and multi doser/system configurations supported
Flow modulation control syncronized with robot TCP speed
Interface to vision systems for quality inspection
C5G APPLICATIONS SOFTWARE
A wide range of application software packages able to manage the most commonly used technological processes.
Each package includes a graphical user interface on the robot teach pendant to allow user input process parameters, customize
process/behaviour and monitor status of process and devices.
SmartArc
SmartArc incorporates a dedicated application software whereby the operator is able to set all the welding parameters and manage
the complete system from teach pendant, by means of a dedicated user interface.
The C5G SmartArc application software provides the user with the complete set of technological instructions for arc welding.
Features include: possibility of programming up to 100 different welding seams for each type of workpiece, real-time control of
the welding process, modification of welding parameters during robot movements, optimization of start, stop and re-start routines,
optimization of weld seams (overlap, search, seam-track, multipass, etc.) plus a library of standard functions ready for use.
The system was designed with a view to enhancing integration and synergy between the robot and the welding unit, in order to
optimize the management of welding operations and cell efficiency.
33
* Software Option
Smart Vision
Interface
Several software interfaces with dedicated communication protocols available for commercial vision systems, for example ISRA,
Perceptron, Oxford, Visionerf, National Instruments, GOM, Servorobot, Quiss
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PDL2
Programming
Language
It is the programming language for writing user programs and applications
It is open to handle up to 4 arms, with 10 axes each one (4 of them can be auxiliary) depending from the hardware configuration
It allows to: move robots arms, follow the program flow, send and get information over files, devices, serial protocols, monitor
the process (up to 255 events and states per program), implement error handling
It includes almost 200 predefined routines and functions with several purposes, as those to manage the arm motion and process
control
It is possible to execute more than 250 multiple programs simultaneously to handle all process control aspects of an application
Controller
System
Software
Our multitasking system software includes: interpolation, position and velocity loops, user interface, networking and language
interpretation
The internal communication is based on PowerLink and CAN for interfacing Servo Units, I/O, Fieldbus
A single controller can direct multiple robotics arms and related equipment
An integrated edit environment, including syntax check and statements execution is available on the robot controller
The controller system software also includes a various set of options in order to accomplish a possible application need
34
* Software Option
Cooperative
Motion *
The cooperative motion feature simplifies the programming of applications where a workcell is composed of a robot and one or
more positioners
This is mainly useful in welding complex shapes or large workpieces
When cooperative motion is enabled, the robot position is defined with respect to the positioner so that cartesian trajectory can
be executed at constant speed while moving the workpiece
Cooperation can be enabled between a robot and its auxiliary axes or between two different arms
There is also the possibility (multi-cooperative motion) for two arms cooperating with the same group of auxiliary axes
belonging to one of the two arms
Synchronized
Arms *
There is possibility of synchronizing the movement of the robot with auxiliary axes belonging to the same arm definition
It is also possible to move 2 different arms in a synchronized way; this means that all the axes start and stop at the same time
Collision
Detection *
The Collision Detection algorithm allows the system to stop the robot arm motion, as soon as any noise force on joints takes
effects
It allows detecting situations such as robot arm collisions with the surrounding environment, stuck tips in the welding operations,
etc.
When a collision condition is detected, the system may enter into a particular status during which the robot gets compliant and
emergency braking takes place
34
C5G SYSTEM SOFTWARE
35
* Software Option
Conveyor
Tracking *
It allows the user to write simple programs for reaching positions defined on a moving conveyor-track: the C5G Controller
automatically compensates the instantaneous position of the conveyor
The conveyor has to be equipped with a position transducer connected to C5G Controller Unit
Cartesian Tracking (recommended for pick and place applications) - the robot is fixed and conveyor tracking is done using a
dynamic conveyor shifted according to the position of the track
Rail Tracking (increases the workspace of the robot allowing to work on huge parts) - the robot is mounted on a slide
Several Arms are allowed to work on the same conveyor
Up to four conveyors can be handled
Robot
Absolute
Accuracy *
This algorithm improves the precision of the robot positioning in the work area by offsetting the kinematic errors and the
deflections caused by the weight of the mechanical parts
The model of error defined for a family of robots is parameterized for each robot
Interference
Regions *
Interference Regions are volumes shared between robot and robot, or between robot and structures, which allow to optimise the
use of the cell inside space, in order to guarantee the collision prevention by defining the geometry of the robot working area
inside volumes
Automatic
Payload
Identification *
An Automatic Payload Identification procedure is available to the user, allowing to obtain the required precision, in the terms of
performance of movements, by correctly defining the payload parameters
It also allows the safeguarding of components
VP2.Builder * VP2.Builder is an application development tool which allows the programmers to create VP2 (Visual PDL2) applications using a
graphical interface for setting all attributes of the objects destined to be viewed on the programming unit of the controller
Sensor
Tracking *
The sensor tracking environment allows the robot to progressively move away from disposition concordantly with the request
coming from a sensor
This is obtained keeping a deviation vector that is applied to the nominal programmed position
C5G foresees a preset of sensors integrated in the control system hardware; it also foresees external sensor which can be
mounted, for example, on the tip of the tool (laser camera on the welding torch, like in ARC application, or with joint type
weaving)
35
36
VP2.Frames * VP2.Frames application program allows VP2 pages to be displayed on a PC (equipped with a Java runtime), being no longer
limited to be viewed on the C5G programming unit only
The C5G Controller, must be connected on the PC where the VP2 pages are displayed
* Software Option
WinC5G
PC
Program *
It is the interface, on PC, to the C5G Robot Control Unit
It is based on the TCP/IP protocol (Ethernet connection to the local network or point to point connection, remote connection via
internet, FTP server mode connection)
It allows to: directly issuing commands to the Control Unit, viewing and transferring files installed on the robot, editing and
syntax checking users programs, looking for occurred alarms (with related cause and remedy) and actions
It also foresees an extension available as WinC5G Full (system software option which includes, as main functionality, a dedicated
menu for positional verification and/or conversion (e.g. linear shift, mirror) of positional values of already existing programs
Smart
Sim Station
Smart Sim 3D-Lite is a powerful system for 3D simulation of Comau robotized cells
SMART Sim 3D-Lite facilitates easy simulation of robotized manufacturing cell and allows you to record the simulation in a 3D
interactive movie to deliver to the customer
SMART Sim 3D-Lite is a powerful system for layout arrangement and design support
Vertical functionality allows users to optimise the positioning of the objects Robot / Positioners / Fixtures in vertical cell
SMART Sim 3D-Lite enables cell/line installation time reduction
SMART Sim 3D-Lite Simulation is compliant with RRS 1 specification for cycle time estimation and incorporates accurate
arrangement of the manufacturing cell/line and offers total user control on the layout and simulation to optimise the virtual
scenario Robot path /Object relations, thereby ensuring the best possible results. It generate collision-free optimised path
SMART Sim 3D-Lite is a powerful system to perform training
C5G PC SOFTWARE
37
Services & Training
Robotics Services
The satisfaction of our customers is always at the top of Comau Robotics strategy. Prompt and flexible
after-sales service close to customers throughout the life cycle of their equipment. A complete range
of services allows the customer to maximise the performance of Comau Robotics solution.
Help desk
Commissioning
Robot & PLC Programming
Service
Maintenance & Refurbishment
Support to Production
Field Modification & Retrofit
Hardware & Software upgrade
Service Contract Management
Service
Training at either the Comau Training Center or customers sites with multi-language sessions
On-line support through remote diagnostics and remote aids enabled by the connection
capacity of the new robot control C5G
Activities developed by experienced technicians at customers site, delivery of spare parts,
repairs and re-conditioning services, world-wide maintenance plans
Supply of spares/repairs for at least 10 years after
product end of production
Exchange repairs & revision on price list
Quotes for repair obsolete material not in price list
Maintenance & Refurbishment Contract
Tailored Service Contract
Spare Parts
Repairs
Service Control Sales
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Training & Educational Courses
We offer extensive and complete training courses for programmers, maintenance experts and robot
operators with multi-language sessions held at Comaus Training Center or at customers site by
qualified skilled instructors with field experience.
Courses can be held in multi-languages, with native-language teachers or through the assistance of
interpreters; complete and detailed documentation concerning course and a certificate of attendance
is issued upon completion of training courses.
Training courses held by field skilled teachers
Training area with 4 robotized cells and dedicated rooms
Training in customer language at our site or customers site
Tailored courses on customer need
Training on the job
Courses from basic maintenance to advanced programming and diagnostic
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www.robotics.comau.com

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Sales +39 011 0045406 sales.robotics@comau.com
Service +39 011 0045479 service.robotics@comau.com
The information contained in this catalog is supplied for information only. Comau S.p.A reserves the right
to alter specifications at any time without notice for technical or commercial reasons. The illustration does
not necessarily show the products in their standard version. Printed in Italy by Multigrafica - 06/12 - Turin

Brochure Gamma Comau Robotics

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