MOTOMAN NEWS

ISSUE 20
MOTOMAN
NEWS
Customer magazine of YASKAWA Europe GmbH, Robotics Division
TRADE FAIR
Rapid development in the
packaging market
REPORT
Jungheinrich AG:
Logistics made easy
with MOTOMAN robots
REPORT
NedCar:
165 MOTOMAN robots
for highly flexible production
REPORT
Nibe AB:
Made-to-order production
with shorter lead times

2
FOREWORD • CONTENTS
New organisation and products strengthen YASKAWA in Europe
Dear customers and partners,
Dear colleagues,
Since last year’s merger of Motoman and Yaskawa Electric to form the new YASKAWA
EUROPE GmbH (YEU), we can look back on eventful and interesting times in the Robotics
Division.
The past year was characterised by a tempestuous economic recovery in Europe. Driven by
the automotive industry, the demand for robots and automation systems has risen sharply.
Real demand and new orders have vastly exceeded even our optimistic planning targets.
As pleasing as this situation may be, following on from the major economic crisis, which
was triggered by the collapse of Lehman Brothers, we are facing enormous new challenges.
The main task is to master the explosive influx of new orders, in terms of personnel
and logistics, and maintain acceptable delivery times for our systems acceptable.
Thanks to our logistics and warehousing policies, we are in a position to meet the huge
increase in demand for standard robots and have been able to avoid the supply shortfalls
that many expected and feared in the wake of this spring’s earthquake in Japan.
With reference to the fusion with the drives division of YASKAWA, now the Drives &
Motion Division, we have adapted structures in order to activate synergies between the
different product lines for the benefit of our customers. We have already synchronised
our sales activities for robot and drive components, enabling us to offer a broader product
range and more comprehensive solutions competence.
In this context, the processes in the Robotics Division have also been adapted to the new
challenges so that we are now in a good position to exploit our potential – both for you, our
customers and partners, and also for our workforce – and pursue a long-term growth policy.
The market launch of our new MOTOMAN MPP3 delta robot complements our range in
the field of picking-packing-palletising applications. Indeed, we can confidently claim to
offer the most comprehensive, and the most high-performance range of products for the
packaging, food and beverage industries.
With our newly completed portfolio, we will now be focusing our attention on this area and
providing a major boost to the use of robotic technology in the field of “PPP”. At the same
time, we shall also be continuing development work in the welding sector. Our customers
can rely on us as an experienced supplier of robots, cells and complete systems.
The groundbreaking ceremony for the construction of our new European headquarters in
Allershausen, held on 6 September and attended by prominent guests from the world of
politics, as well as numerous representatives of the press, clearly demonstrated our stated
aim of working for further growth in Europe and received widespread public support. This
investment is a clear signal to the markets, to you, our customers and partners, but in
particular also to our workforce:
YASKAWA is adopting a more visible presence and is enhancing not only its product
competence, but also its service competence, so that we can offer our customers even
greater support. To this end, we will also continue to exploit the synergies with the Drives
& Motion Division still further.
I look forward to an interesting and challenging future
as we continue to work together with you.
Yours Manfred Stern
President & COO
YASKAWA Europe GmbH
Contents
Foreword
New organisation and products
strengthen YASKAWA in Europe 2
Latest News
Groundbreaking for multi-million euro
investment in Allershausen, near Munich 3
Girls’ Day 4
The “TheoPrax model” in Munich 4
YASKAWA receives official recognition
as a provider of vocational training 5
Complete solutions from a single source 5
Focus
Next-generation bonding 6/7
Report
Jungheinrich AG, D-Landsberg/Halle:
Logistics made easy with
MOTOMAN robots 8/9
HDG Bavaria GmbH, D-Massing:
Investment in even greater quality 10/11
NedCar, NL-Born:
165 MOTOMAN robots for
highly flexible production 12/13
Nibe AB, Sweden: Made-to-order
production with shorter lead times 14
SYMACON GmbH, D-Barleben:
Mobile Robot Platform RPm
for efficient flexibility 15
Innovation
Delta robot complements the MOTOMAN
product range from YASKAWA 16
State-of-the-art series palletising robots 17
Plug & Play robotic welding system
“MotoWeld-SR350” 18
Trade Fair
“MEDTEC Europe”, D-Stuttgart:
Automation on the advance in
medical technology 19
“Blechexpo/Schweisstec”, D-Stuttgart:
Fully synchronised for greater efficiency
in the welding process 19
“interpack”, D-Düsseldorf:
Trend topic: Cost efficiency and
process efficiency 20/21
“interpack”, D-Düsseldorf:
“Rapid development in the
packaging market” 22
Imprint
MOTOMANNews
Issue 20 (2011)
Editorial Team:
Marion Reisert
robotics@yaskawa.eu.com
www.yaskawa.eu.com
Design/Layout:
Matthias Grießel and
Angela Freiberger, Munich
Production and print:
Druckerei Vogl, Munich
www.druckerei-vogl.de
Authors:
Cecilia Benze, Constantin Bader, Tilo
Dobmeier, Jürgen Goroncy, Paul Hafkemeijer,
Ralf Högel, Hans-Peter Krug, Eddie Mennen,
Oliver Neutert, Ralf Raimann, Marion Reisert,
Torben Schäfer, Ulrike Schulz, Renate Singer,
Alexander Steiger, Stephan Weitkamp
Event
Focus on the aerospace sector 23
Forthcoming trade fairs
Forthcoming trade fairs in 2011 and 2012 23

LATEST NEWS 3
Japanese global corporation YASKAWA reaffirms commitment to bavarian location
Groundbreaking for multi-million-euro
investment in Allershausen, near Munich
The Japanese corporation YASKAWA, the world’s leading manufacturer of industrial robots and drive technology with annual
turnover of over 3 billion euro, is strengthening its European base in Allershausen, near Munich: construction work for the
new headquarters officially began on 6 September with a traditional Japanese groundbreaking ceremony.
Bavarian Minister for Economic Affairs
Dr. Martin Zeil called it a “Joyous occasion
for Bavaria and Japan” and broke the
ground together with YASKAWA’s European
directors Koichi Takamiya (Board of
Directors, Regional Head Europe, YASKAWA
Electric Corporation, Japan) and Manfred
Stern (President & COO, YASKAWA Europe
GmbH). They were ably assisted by
a twin-arm MOTOMAN SDA 10 robot.
Other guests of honour at the ceremony
were the mayor of Allershausen, Rupert
Popp, the Japanese General Consul, Akira
Mizutani, and deputy district administrator
of Freising, Anita Meinelt.
The building company responsible for the
project, Takenaka, was represented by
Tetsuya Sekiya (President of Takenaka
Europe GmbH) and Shiro Osada (Executive
Managing Officer, TAKENAKA Corporation,
Japan).
On course for growth
YASKAWA is investing around 12.5 million
euro in the new, representative headquarter.
This is also a sign of the high goals that
the world’s market leader has set itself for
the European market: “We aim to double
the number of MOTOMAN robots installed
annually in Europe to over 6,000 by 2015,”
explained Manfred Stern, President and
COO of YASKAWA Europe GmbH, on
the occasion of the groundbreaking ceremony.
European head Koichi Takamiya (Board of
Directors, Regional Head Europe, YASKAWA
Electric Corporation, Japan) describes the
strategy thus: “We are positioning ourselves
primarily by means of the added value that
we offer customers with our robots.”
Accordingly, Allershausen, YASKAWA’s
base for its European business activities in
the field of robotics, will see particular emphasis
on central functions, such as total
customer support, research & development,
customer-specific system adaptation
and logistics. The new building will
also accommodate the additional 50 employees
that YASKAWA intends to take on
for this by the end of 2012. At the same
time, these tasks will also become more
centralised.
Showcase for Europe
In addition to this practical aspect, YASKAWA
also sees this new headquarter, which is
visible over a large area, as a showcase
for its European customers. “The showroom
is the highlight of the new building;
it will be impressive,” asserts Yasushi
Ichiki (General Manager Corporate Planning
YASKAWA Europe GmbH).
The plot covers some 14,000 square meters
and is conveniently situated close to
the Allershausen exit from the motorway.
Some of the buildings at the previous site
in the Kammerfeld industrial estate will
remain in use.
Before the actual groundbreaking, Shiro Osada
(Executive Managing Officer, Takenaka Corporation
Japan) scatters rice in accordance with Japanese
tradition. The ceremony was attended by (from left
to right) Bernd P. Bützler (Deputy General Manager,
Takenaka Europe GmbH, in the background) Koichi
Takamiya (Board of Directors, Regional Head Europe,
YASKAWA Electric Corporation, Japan), Dr. Martin
Zeil (Bavarian Minister for Economic Affairs), Rupert
Popp (Mayor of Allershausen), Akira Mizutani
(Japanese General Consul), Anita Meinelt (Deputy
District Administrator for Freising, in foreground) and
Manfred Stern (President & COO, YASKAWA Europe
GmbH, in the foreground).
The outer design of the new building is
based on that of the headquarters of the
YASKAWA Robotics Division in Japan.
The new building is planned to be ready
for use in August 2012.
First cut (from left to right): Shiro Osada
(Executive Managing Officer, Takenaka
Corporation Japan), Akira Mizutani (Japanese
General Consul), Dr. Martin Zeil (Bavarian
Minister for Economic Affairs) and Koichi
Takamiya (Board of Directors, Regional Head
Europe, YASKAWA Electric Corporation, Japan).
Second cut (from left to right): Tetsuya Sekiya
(President, Takenaka Europe GmbH), Rupert
Popp (Mayor of Allershausen), Anita Meinelt
(Deputy district administrator for Freising) and
Manfred Stern (President & COO, YASKAWA
Europe GmbH, in foreground).
(From left to right:) Manfred Stern (President &
COO, YASKAWA Europe GmbH), Koichi Takamiya
(Board of Directors, Regional Head Europe,
YASKAWA Electric Corporation, Japan),
MOTOMAN SDA 10 robot, Bavarian Minister for
Economic Affairs Dr. Martin Zeil and Japanese
General Consul Akira Mizutani.

4 LATEST NEWS
On 14 April 2011, Girls’ Day events were held at YASKAWA Europe in Eschborn
for the second time. All available places were already booked after just 2 days.
Girls from 10 to 13 years of age from nearby schools took up the offer, together
with 2 daughters of colleagues.
What is the objective of Girls’ Day?
The name is largely self-explanatory. Particularly
in technical professions, women are
largely under valued.
The aim is to make girls aware at an early
age that many typical “men’s jobs” can also
be attractive and interesting for women.
At YASKAWA, this means the professions
of engineers and electronics technician for
devices and systems.
The girls were introduced to both professions,
with their widely differing career
paths.
At the start of Girls’ Day, the girls stated
what careers they currently envisaged for
the future. About two-thirds of the children
already had clear ideas: teacher, zookeeper,
vet, architect or writer.
A list was then drawn up of the different
careers and opportunities to be found at
YASKAWA. The spectrum ranges from
accountancy, human resources management,
wholesale and international trade
and IT specialist to electronics technician
for devices and systems and engineer.
Many of these jobs are performed by
both men and women. In technical functions,
however, women are in a small
minority. This is why the engineering profession
was presented first at Girls’ Day.
This profession requires university or technical
college entrance qualification, which
means that children already need to make
certain decisions at an early stage. Engineers
are trained in a wide range of different
fields: aerospace, mechanical engineering,
chemical engineering, communications
technology, mechanics, construction engineering,
mechatronics, biotechnology and
environmental technology.
These functions are also used in many different
areas of the companies they work
in, such as: development, planning, sales,
technical consultancy, application consultancy,
inspection and assessment, technical
writing or customer service.
After this introduction to the theory, the
girls headed for the laboratory. Here, Karen
Reiter described her career and her work
as a software engineer at YASKAWA.
Some of the girls ran two motors on the
test stand and adjusted the speed and
torque.
On a visit to the EEU workshop, trainee
Christopher John reported on his work during
his training as an electronics technician
for devices and systems and showed the
girls some practical examples of his work.
These included a workpiece produced for
his intermediate exams.
A glance into the warehouse was followed
by lunch in the canteen where COO Manfred
Stern addressed the girls with friendly
words.
The highlight of Girls’ Day came in the second
half: in the showroom, a two-armed
robot showed how it can apply a name to
a ruler. All the children then received a
ruler with their own name on it.
In the YASKAWA Academy, training manager
Torben Schäfer demonstrated robots
covering a wide range of different tasks:
from robots for screen coating applications
and welding robots to robots for vehicle
wheel handling operations.
The most exciting thing for the girls, of
course, was having the opportunity to
control a robot by themselves. Once again,
it was amazing to see how quickly children
pick up the concept of using the teach
panel and the robot and how they made
“child‘s play” of robot operation.
At the end of Girls’ Day, the girls had
to write down their intended career once
again.
It came as no surprise that there was significantly
increased interest in careers with
robots. To round off the day, the participants
were all given a number of small
presents and a group photo was taken. The
girls were highly enthusiastic about their
visit to YASKAWA and – who knows? –
perhaps some of them may one day find
themselves working in a technical profession
with our company in about 8 to 15
years.
The “TheoPrax model” in Munich
Inter-school TheoPrax project on the topic of “creation” with performing artist Berkan Karpat.
The objective of the “TheoPrax model”
project in Munich is to develop ideas for
project work of a serious nature for secondary
schools and commercial colleges
in Munich. TheoPrax is a teaching and
learning system that combines theoretical
and practical elements in the skills development
and career guidance of young
people. For seven months, 45 pupils from
three Munich schools worked together on
the project “I am reaching for the stars
and building the 21st century – even if
only for a moment”. Based on an idea by
Munich-based performing artist Berkan
Karpat, and under the guidance of the Department
for Employment and Economic
Affairs, the pupils set up an artistic installation
depicting the topic of “creation”
and combining audiovisual elements and
the programming of a MOTOMAN robot.
The resulting work was on show at an
exhibition in Munich from 26 to 28 July
2011.
Seven pupils from the Helen-Keller-Realschule confidently demonstrated the topic of “creation” with a
specially programmed MOTOMAN industrial robot: the Big Bang starts with the bursting of balloons,
the element “wind” is created by the loading and unloading of plastic parts, and language is
symbolised by the writing of the word “HELLO”.

LATEST NEWS 5
AZWV funding of YASKAWA training courses
with training vouchers:
YASKAWA receives official recognition
as a provider of vocational training
15 training initiatives for the MRC, XRC and NX100 robot controllers and the
latest-generation DX100 have been evaluated and AZWV-approved.
In addition to the range of services already
provided, the YASKAWA Academy
is now also able to offer employee qualification
during short-time work. Following
general approval of the company,
15 training initiatives for four controller
generations have already been tested
and given an official seal of approval. The
local employment agency of the applicant
is responsible for issuing the vouchers
following an interview.
Further information can be found under
“Training” on the YASKAWA website
(www.yaskawa.eu.com) or obtained directly
from the Training Center Eschborn
(Tel. +49 (0)6196 777 25 70).
FOCUS
Robot-based packaging solutions from YASKAWA
Complete solutions from a single source
The robotic automation of packaging tasks increases the flexibility, productivity and reliability of processes, irrespective
of the specific branch of industry. With the MOTOMAN range, YASKAWA offers the required elements for packaging lines:
from product picking and packing to final preparation of the pallets ready for shipping.
A uniform, overall technical solution for
the entire packaging process may take
the following form: an MPP3 delta robot
picks up the product in its primary packaging
– e.g. a packet of sweets – and deposits
it at high speed in a carton or
shallow tray. In a second step, a 5-axis
MOTOMAN MPK2 robot takes over. With
its streamlined gripper and 400 mm long
Z axis, it is ideal for loading crates and
deeper trays. With a payload capacity of
2 kg, it manages up to 133 cycles per
minute. This complex, high-speed process
is managed by the MOTOpick process management
software. This software controls
both the integrated image processing
functions and conveyor tracking. Correct
positioning of the correct product is thus
automatically assured at all times. Moreover,
MOTOpick provides the system
operator with a user-friendly interface that
can be used for the quick and straight
forward creation of new patterns.
The remaining packaging process for the
previous pre-grouped components is controlled
by, for example, an MPK 50, one
of many options offered by YASKAWA’s
wide-ranging robot portfolio.
It is a four-axis robot with a payload capacity
of up to 50 kg and an almost rightangled
working envelope that it covers
at high velocity, making it ideal for this
task. The MOTOMAN MPL series, designed
for the downstream palletising
operations, is also designed with a 4-axis
configuration and comprises the widest
range of 4-axis robots on the market. The
robots of the MPL series are available
for payloads from 80 kg to 800 kg and
palletising heights of over 3 meters. They
are very fast and, thanks to their large
workspace and compact design, they can
be integrated into system concepts with
great flexibility. A comprehensive range
of software solutions completes the total
package from YASKAWA. The simulation
of complex cells in the planning phase
and the programming and control of the
palletising system are simple with the
wide range of products and services from
YASKAWA.
Robotic packaging lines such as this offer
decisive advantages over conventional
linear or gravity packers: they are gentle
on products, can be used is a flexibly way
and take up little space. Highly developed
control technology produced in house and
special application software complete the
total package for PPP applications from
YASKAWA.
MPP3 MPK2 MPL series

6
FOCUS
YASKAWA intends to revolutionise bonding and sealing applications
using a newly developed process
YASKAWA presents pioneering
adhesive bonding technology
A highly dynamic joining process ensures that gap variations are automatically compensated for whilst maintaining
a constant robot travel speed. The overall system features high-tech robotics components, dispensing technology and
sensor systems, and delivers unprecedented performance.
The six-axis MOTOMAN MH50 robot delivers supreme continuous path performance.
For decades, robotic welding has been
one of the central core competencies of
MOTOMAN. Following the merger with
its parent company, MOTOMAN now trades
as YASKAWA Europe. “Those with
high levels of welding expertise also
have an advantage when it comes to
related processes, such as bonding and
sealing,” affirms Ralf Raimann, bonding
specialist at YASKAWA. “Particularly with
regard to path following performance, the
demands on the robot are very similar.
Welding processes are often combined
with, or replaced by, adhesive bonding
processes. We are therefore working in
familiar territory.”
Market analysis forecasts significant
growth potential in the areas of bonding
and sealing. The number of applications
is steadily increasing in a wide range of
industries, from automotive and subsupplier
industries to aerospace and even
the defence and pharmaceutical sectors.
There is also potential for growth in areas
such as white goods, the construction
industry, solar power systems and the
processing of high-tech materials. It is for
applications such as these that the newly
developed process, for which a patent application
has been filed, is set to become
a state-of-the-art technology.
Pioneering bonding system
YASKAWA is using a pilot system, which
is soon to be used in practice, to demonstrate
next-generation bonding.
“We developed our pilot system in response
to a specific customer enquiry,”
explains Raimann. “Its task is the automated
joining of workpieces for the con-
struction industry with single-component
material. The advantage is that it is not
necessary for the workpiece to be manufactured
with great precision as our technology
enables the sealing of different
gap widths, from two to seven millimetres,
whilst maintaining a consistently high
process velocity.”
The innovative bonding system developed
by YASKAWA consists of three core
components: a six-axis MOTOMAN MH50
robot, a highly dynamic dispensing system
and the sensor system, which plays a key
role in establishing the gap width. Exact
in-line measurement of the gap width
with a 2D laser sensor is the basis for
controlling the complex process.
Various parameters – primarily the travel
speed of the robot and the dispensing
quantity – have to be controlled in real
time and coordinated with each other.
Control of the process is based on a
number of interlinking control loops.
With the innovative DX100 robot controller,
YASKAWA has achieved outstanding
process reliability and can process a wide
range of medium and high viscosity singlecomponent
materials in the system.
Highly dynamic dispensing system
In the opinion of suppliers, the Modis
dispensing system (Modular Dynamic
Dispense System) from Hilger & Kern, is
the dispensing technology of the future.

FOCUS 7
The new bonding process can be used to seal different gap widths reliably and efficiently.
Photos: Ralf Högel
According to Ralf Raimann, the YASKAWA
bonding cell combines innovative dispensing
technology with the dynamic
characteristics and flexibility of MOTO-
MAN robots to produce a complete system
with unprecedented performance:
“As far as cost effectiveness and productivity
are concerned, we are setting new
standards in bonding and sealing applications.”
Furthermore, the modular nature of the
dispensing system allows a wide range
of applications to be considered. Process
reliability is ensured for materials such
as epoxy resins, polyurethanes and MS
polymers, as well as polysulphides and
silicone. Depending on the size of the
dispenser, flow rates of 120, 600 or 1,500
cubic centimetres per minute are possible,
with the system running at a capacity
of 1 to 100 percent. The range of
possible applications for the YASKAWA
systems is thus virtually limitless.
Alongside smaller turntable systems, covering
a distance of 200 x 200 millimetres,
gantry systems with multiple robots
covering twenty metres or more are also
conceivable.
The process is suitable for joining glass,
plastics, metal and wood. The 2D laser
sensor, which detects the gap width, plays
a decisive role here; this is particularly
important in the case of transparent
materials. “The sensor specialists from
Keyence not only have the right sensor for
every application, they also have expertise
in configuring and setting up the correct
parameters of the sensor systems,”
says Ralf Raimann from experience.
Real-time process control
YASKAWA uses the DX100 robot controller
to control the complex bonding process.
The controller processes the flow
of information in its operating system.
It also enables ultra-short control intervals,
measured in milliseconds, upon which
the dynamic process relies. With a view
to maximising performance, YASKAWA
places great importance on the strict separation
of the robot controller and the
dispensing system controller. An interface
with real-time capabilities from the
robot controller to the dispensing system
ensures process oriented internal communication
between the robot and the
dispenser.
YASKAWA has selected the six-axis
MOTOMAN MH50, which meets all the
key requirements for bonding and sealing.
Expert Ralf Raimann summarises the advantages
of the MH50 as follows: “The
path-following performance of the MO-
TOMAN MH50 is outstanding in its class
and it is also fast and reliable. It is highly
compact and yet has a reach of over two
metres with a payload of 50 kg. Combined
with the DX100 controller, it is thus
the perfect machine for bonding and
sealing.”
The pioneering bonding system can be
used for the automatic, reliable and costeffective
joining of workpieces with different
gap widths whilst maintaining a
consistent high travel speed of the robot.
This creates additional value potential
for the user with more flexible bonding or
sealing processes and pre-production.
The flexibility of the process and the ability
to compensate for gap widths of between
two and seven millimetres allow
considerably greater tolerances in preproduction.
This eliminates the need for
cost intensive precision manufacturing in
a wide range of applications, resulting in
enormous potential savings for the user.

8
REPORT
Logistics made easy
with MOTOMAN robots
YASKAWA Europe GmbH supplies equipment to many OEMs and their suppliers, not only for welding tasks
in exhaust gas systems and vehicle chassis; the Allershausen based company also offers custom tailored and
competitive solutions for other industry sectors.
Jungheinrich AG, one of the world’s largest suppliers of
industrial trucks and logistics solutions, has opened a new
plant in Landsberg, near Halle (Germany), for the manufacture
of electric pallet trucks. MOTOMAN welding robots
are responsible for the manufacture of frame components.
The new plant is an independent “Center of Excellence”
and houses all management, development and production
functions for electric pallet trucks. Since 2007, Jungheinrich
has invested about 30 million euro in the new production
facility which currently has a workforce of 80 people.
Pilot series production commenced on 1 July 2009. Since
the summer of 2010, all electric pallet truck variants are
manufactured in Landsberg, in a production area covering
around 17,000 square meters.
For the EJE and ERE series, Jungheinrich welds important
components with the aid of state-of-the-art robot technology.
The load frames, including the forks, are produced
by MOTOMAN UP20MN robots; the drive frames are
taken care of by EA1900N welding robots. The blue robots
are equipped with welding technology from Fronius which
is integrated into the systems by an external service provider.
The welding cells also feature numerous fixtures and manual
welding stations.
Control of the systems is based on Siemens PLC technology,
but the NX-generation controller was developed
entirely by YASKAWA. Furthermore, the welding specialist
wrote the first programs together with Jungheinrich employees.
The service technicians have meanwhile developed
over 1,000 programs, which are stored on a central
server. The last of the required welding programs were implemented
in the spring of 2010.
Cooperative welding process
For production of the load frames and forks, Jungheinrich
set up three welding cells, each containing two robots from
Allershausen. Jungheinrich designed the welding cell in such
a way that welding can be carried out on one side, while a
finished part is removed from the other half of the system
and the fixtures are reloaded. This layout requires welding
robots with a large working area. The UP20MN has a unique
reach of 3,106 millimeters and thus ensures efficient utilisation
of the workspace and improved productivity.
The two robots in each cell are mounted on a shared track,
and the 250 kg bulk packs of welding wire also travel on
the axis.
Job sharing is the name of the game in the cells: one robot
welds several individual components together to form the
forks, while the other does the same for the load frames.
Once the second robot has completed its program, it helps
its “colleague” to weld the forks.
Jungheinrich does not exploit the available welding performance
of the robots to the full in order to keep wear and
tear to a minimum.

REPORT 9
By way of preparation, the operators load the individual
components of the load frames and forks into the fixtures
and tack weld them together using manual welding power
sources. They then scan the code of the parts into the
controller so that the welding robot will select the correct
welding program. For each product, there is a suitable
welding program on the server with a range of different
subprograms. Jungheinrich produces a number of different
load frame variants and forks ranging in length from 800 to
2,400 millimeters, with varying widths and thicknesses.
Once the robots have completed their tasks, an operator
unloads the finished workpiece from the fixture and visually
inspects the seams.
Lean production with streamlined robot technology
Jungheinrich manufactures the drive frames of the electric
pallet trucks in two cells, each containing two MOTOMAN
EA1900N series welding robots. These standard welding
robots feature an integrated coolant and weld current supply.
This results in increased service life of the cables, fewer
interruptions to operation due to damaged cables, and
a more streamlined robot contour.
The work sequence from the loading of the individual parts
to the offloading of the finished drive frame to the material
flow is similar to that for the load frames. A slight difference
is that the robots each concentrate on their own
tasks and do not help one another out.
Load and drive frames are made of ordinary mild steel so
no special welding technology is required.
Both components are subsequently powder coated and
then screwed together during final assembly.
planning phase was completed in September 2008 and
YASKAWA was awarded the contract for the project.
One reason was that Jungheinrich already appreciated the
quality and reliability of MOTOMAN robots from existing
applications.
MOTOMAN then implemented Jungheinrich’s concept
requirements: of particular importance to the industrial
truck specialist was weld quality, an optimal material
flow including logistics concept, occupational safety and
accessibility for the operators. Additional requirements
included factors such as ergonomics, ease of cleaning,
compact dimensions and adaptation to the Jungheinrich
color scheme. The systems were successively installed and
programmed in the spring of 2009. Despite the extremely
tight time frame, production was able to commence on
schedule in July 2009. The quality, design and cleanliness
of the welding cells with MOTOMAN robots set new
standards for comparable industrial systems.
Development goal: “Best in Class”
Initial planning for the welding cells was carried out in
February 2008. In addition to YASKAWA, other competitors
also submitted corresponding concepts which were then
successively optimised in partnership with Jungheinrich. The

10
REPORT
Welding robots
Investment in even greater
HDG quality
A robot track, a robot arm, a positioner and a “Teach Pendant” – these are the principal elements of the
MOTOMAN EA1900 welding robot that recently joined the production team at HDG Bavaria GmbH.
For the manufacturer based in Lower Bavaria, this new industrial robot constitutes an investment in the
company’s future. In the following report, you can find out how the new high-tech machine works.
Exact weld seams
and strong joints –
these are the
work of MOTO-
MAN robots.
Before the welding robot can weld parts for boilers and
accessories, the individual parts must first be manually
tack welded. An HDG employee accurately positions the
components in a clamping fixture (welding gauge) and
tacks them in several places. In order to keep distances
short, this is done at a specially installed workstation
immediately next to the welding robot.
Perfect seams – down to the very last corner
An operator trained in working with the welding robot then
loads the tacked assembly into the positioner – a fixture on
the robotic workstation in which the parts are held in place.
The positioner is able to support workpieces weighing up
to 500 kg and measuring up to 160 x 250 cm. Furthermore,
the parts to be welded can be rotated through 360° about
their own axis on the positioner, as well as being moved
vertically. This enables the welding torch to join the metal
parts together, even in positions that are difficult to reach.
Particularly when it comes to welding worm drives, this
function for flawless quality of the products is indispensable.
Since it is also possible for the welding torch to rotate
through 360°, the robot also welds uniformly around curves.
HDG uses Tycon 18 gas with the MOTOMAN EA1900.
This is currently supplied from a bank of 12 gas cylinders
that are stored outside the production shop.
Simple programming
Once the HDG employee has clamped the workpiece onto
the positioner, he moves to the operator panel and starts
the welding operation. The robot only commences its work
when there are no people left in the zone safeguarded by
the photo-electric barrier.
In order for a welding process to be carried out successfully,
the HDG employee must program the welding robot
for each individual part. This is done using the so-called
“Teach Pendant”. This teach pendant with touch screen
has a user-friendly menu interface and is quick and easy to
program.
As the dress package with the gas supply hose and wire
feed runs directly along the robot arm and is thus located
in a fixed position, there is no need to take the routing
of the hoses into consideration during programming. This
saves time.

REPORT 11
Installation diagram
of the new
welding robot at
HDG.
Advantages of the welding robot
While the robot is working at one welding station, the
second welding station can be prepared.
This means that the HDG employee loads another assembly
onto the second positioner another object that is to be
welded. This largely eliminates idle time for the MOTO-
MAN EA1900.
In addition to this advantage, and the extremely short programming
time, HDG Bavaria GmbH opted for the welding
robot for the following reasons:
In conjunction with the laser cutting system purchased
the year before last, which is used for the precision manufacture
of the individual parts, the robot has enabled HDG
to optimise its already high quality even further. For the
production team that works with the welding robot, the
first implication of the new investment was a five day
training course at MOTOMAN. The objective of the coming
weeks is to become familiar with the robot and to optimise
its utilisation.
• Cycle time reduction
• Even greater welding quality (e.g. stable arc, optimal
torch position, ability to weld round radius)
• Greater cost effectiveness
1
2
1 The dress package is permanently routed
through the robot arm.
2 The robot moves backwards and forwards
on the robot track.
The welding robot in action.

12
REPORT
165 MOTOMAN robots for
highly flexible production
at NedCar
The state-of-the-art NedCar automotive plant in Born (Netherlands) has been making cars for over 40 years.
Cars that have been produced there over the decades include the “DAF33”, the “Mitsubishi Spacestar”,
the “Mitsubishi Carisma”, the “Smart” and various Volvo models. Models currently rolling off the lines there
are the “Mitsubishi Colt” (3-door and 5-door versions) and the “Mitsubishi Outlander”. NedCar is meanwhile
a 100 percent subsidiary of the Japanese Mitsubishi group.
are also used in the production line as welding robots.
These execute MIG weld seams and also a number of
MIG-brazed seams. The reliable “MotoWeld” arc welding
technology is used for this application.
The wide range of different makes and models that have
been produced at NedCar illustrates just how flexible this
plant is. In order to achieve this degree of flexibility, NedCar
makes use of versatile, modern manufacturing technology.
When it comes to robotic technology, NedCar turns to
MOTOMAN systems from YASKAWA.
Bodyshop
120 MOTOMAN robots are used in the bodyshop. Thanks
to the extremely effective programming, it was possible
to commence production of the “Mitsubishi Outlander”
within two weeks.
Four different types of MOTOMAN robot are used in the
production of the Outlander. The MOTOMAN ES200N and
MOTOMAN ES200RN (as shelf type models) are primarily
responsible for handling and spot welding tasks.
The robots often switch from one task to another with the
aid of automatic tool changers. All spot welding guns are
servo controlled for optimal velocity and weld quality. The
electrode tips of the spot welding guns are automatically
dressed when worn or fouled by the zinc layer on the body
panels. The new “Tool Center Point” (TCP) position is then
automatically calibrated and corrected.
Vehicle roof
Another interesting process is the clinching process used
for joining the roof to the vehicle body. First of all, the roof
is automatically loaded by one robot; two MOTOMAN
robots with clinching guns then carry out all the joints.
MOTOMAN SSA2000 and MOTOMAN EA1900N robots
Door, hood and tailgate
In the manufacturer of doors, hoods and tailgates, the
flexible roll hemming technique is used.
Adhesive is applied to the inner and outer parts at the hem
seam and the parts are automatically joined together.
Finally, a MOTOMAN ES200N with a special roll hemming
head bends the edge of the hem. The workpiece is automatically
rotated by a servo controlled turntable and the
positioner is controlled by the robot.
This concept is considerably more cost effective than
conventional hemming presses or so-called “table-tops”
and easier to adapt in the case of component modifications.
Final assembly
In most automotive plants, few if any robots are used in
final assembly. At NedCar, industrial robots have been
used in final assembly since the mid-90s. The number of
MOTOMAN robots performing all manner of tasks there
has reached 45 in the mean time.
Wheels
In the fully automated wheel assembly station, for example,
the wheels are brought to the production line on a conveyor
belt. Using an automatic feed system, a small robot
loads the nuts individually into the assembly grippers. The
assembly robots then take the wheels and measure the
exact position of the thread on the vehicle. Using these
measured values, the assembly position is calculated and
the wheels are screwed on. The torque is automatically
monitored and documented for quality control.
Cockpit
In the fully automated cockpit assembly station, the preassembled
cockpits are transported to the production line
on a conveyor belt.
While one robot removes the cockpits from the conveyor,
another industrial robot measures the exact position of the
assembly holes in the vehicle body. Using the measured
data, the cockpit is precisely positioned in the vehicle body
and another robot screws the component to the body.

REPORT 13
Photo on left:
Arc welding and
MIG brazing with
“MotoWeld-SR350”.
Photo on right:
Roll hemming.
Photo on left:
Clinching, car roof.
Photo on right:
Cockpit assembly
with automatic
screw fastening.
Photo on left:
Assembly and
adhesive bonding
of windshields.
Photo on right:
Seat installation.
Other robotic applications in final assembly are the fully
automated bonding and assembly of glass panels (front,
rear and side), the placing of seats and the automatic filling
of all fluids. All in all, this is a good example of the universal
range of potential applications for robotic technology.
Local support from YASKAWA Benelux
Training of NedCar employees and after-sales service are
carried out directly by YASKAWA Benelux.
In this way, NedCar receives optimal local support for
modern automotive production tasks.

14 REPORT
Nibe AB, Sweden:
Reduced lead time
with production on demand
Short Facts
Customer:
Product:
Industry:
Application:
Nibe AB, Sweden
Stoves
Metal fabrication
Press-brake tending
System components: Four identical robot cells with
– One MOTOMAN UP50N-35
– Servo powered floor mounted robot
– TSL-1000SN robot track
– Multi-function grippers
– Programming
– Robot controller NX100
The MOTOMAN robot has everything at hand on the accompanying
equipment trolley: A complete set of small sheets, multi-funcional
grippers and regrip stations.
Results: – Lead time reduced with 90%
– One human operator, four robot cells
Challenge
Nibe’s 10 robotic arc welding cells (8 from
MOTOMAN), each producing their own
specific stove type, were being supplied
with pressed parts from several manual
production lines located far away. Valuable
resources were being spent in transport,
storage and logistics to keep up
production, and Nibe wanted a more cost
efficient and productive solution.
Steps of the press brake cell.
Solution
The whole production operation is initiated
by the arc welding cells. When they
are about to run out of parts for a particular
stove type, one (or two) of the
four press brake cells automatically starts
batch production in order to supply components.
The MOTOMAN press brake cell
selects the right program and gripper
tools, stocks the accompanying trolley
with small sheets and then completes
the bending process. Ready-made parts
travel in a pallet with RFID information
on an automatic conveyor system to the
awaiting arc welding cell. Only one human
operator is needed to supply materials
and keep the four press brake cells in
operation.
Results
Production on demand with the lead time
reduced by 90% means that it is possible
to have a vast product range without
keeping a large inventory. With all the
innovative equipment, such as multi-functional
grippers, tool changing, pallet racks
and pallets that are stocked with many
different sheet types, etc., the four pressbrake
cells are capable of handling up to
80 different sheet sizes. Due to the fact
that a majority of the heavy sheet metal
parts are now handled by robots, important
benefits also include improved ergonomics
and fewer injuries.

REPORT 15
Mobile Robot Platform RPm
for efficient flexibility
SYMACON GmbH, a specialist supplier of handling and assembly equipment based in Barleben (Germany), has developed a
“Mobile Robot Platform RPm” which can be used with MOTOMAN robots from YASKAWA. The modular series cell allows
unprecedented cost effectiveness and flexibility for automatic machine tending processes.
Until now, the following applied to the
automated loading and unloading of machines:
the higher the degree of automation,
the more limited the flexibility of
the feeder system. In other words, a fully
automated machine tending system can
generally only be implemented for a single
machine. Systems allowing variable
operation, on the other hand, are less
efficient.
The new development meets this two fold
challenge by combining a universally deployable
mobile platform with, for example,
high performance MOTOMAN robots. In
terms of price, the modular series cell
thus offers a highly interesting alternative
to equivalent dedicated solutions. Another
benefit: the customer can take advantage
of a tried-and-tested basic system that can
nevertheless be customised to individual
requirements.
Construction
The emphasis of the design was on maximum
flexibility: a solid, welded substructure
forms the basis of the robot platform.
It can be moved around production shops
with a fork lift truck at extremely short
notice. This means that the machine tending
cell can be used in a flexible way at
various machine tools. The advantages
of this system becomes apparent in the
case of varying levels of utilisation, production
change overs and the addition
of new tasks. An intelligent referencing
solution with stored sequences further
enhances the flexibility of the system.
Conversion times are thus minimised, and
the machine tools are very quickly available
once again.
The modular nature of the system means
that the substructure can be fitted with a
wide range of components. The “Mobile
Robot Platform RPm” thus unites a complex
array of technical and technological
options in an area of just 1.5 x 2.5 metres.
At the heart of the machine tending cell is
the robot installed at the center. Compared
with other solutions – e.g. gantries –
robots offer extreme flexibility. The universal
platform is suitable for various models
in YASKAWA’s MOTOMAN range.
Versatile applications
The flexibility of the platform itself is reflected
in the wide range of potential applications
for the robot in the production
of workpieces: robots such as the MOTO-
MAN MH6 or HP20, configured according
to user-specific requirements, can support
such tasks as grinding, turning, deburring,
inspection or measurement.
All work steps can be combined with high
flexibility without the need for rigid specifications.
Guides installed directly on the platform
allow the robot to be repositioned manually
by the operator. This ensures free access
to the workspace of the machine tool.
In conjunction with the two safety doors,
this functionality also enables convenient
tool and clamp changing.
The supply of unmachined parts and the
handling of finished parts weighing up to
20 kg can be implemented using a wide
range of tried-and-tested solutions: the
machine tending cell can be configured
with all manner of conveyor belts, chain
conveyors, baskets, pallets, drawer systems,
etc. A NOK/SPC setdown point can
also be accommodated.
The possibilities of the “Mobile Robot
Platform RPm” thus go far beyond those
of a dedicated machine tending solution.
Increasingly complex production requirements
are supported by a large number of
exchangeable process modules.
Measuring devices, deburring devices,
labeling systems, turnover stations, image
processing systems and more can all be
implemented in the configuration. An oil
thrower, for example, can be used after the
grinding of gear wheel teeth to remove oil
from the workpiece, thus countering the
risk of oil entrainment problems.
User-friendly operator control
with a standardised mobile panel.
Reference application
At Zerbster KmB Technologie Gesellschaft
für rationelle Fertigung mbH, a sub-supplier
to the automotive industry, the robot
platform has been running for over a year
in three-shift operation. The company
manufactures parts, components, modules
and systems for motor vehicles and
the mechanical engineering industry. Current
daily production output is about
35,000 parts. The range of products and
services of KmB Technologie covers all
areas of cutting and non-cutting machining
with great manufacturing depth, as
well as heat treatment and assembly.
The Mobile Robot Platform carries out an
ever changing range of different tasks.
For Steffen Gädicke, Head of Sales/Purchasing
at KmB, it was the flexibility of
the system that was the decisive factor
behind this investment.
Equally important was the fact that the
costs were lower than those for conventional
inflexible solutions: “Financial pressure
in our branch of industry is enormous.
We can only stay ahead of our competitors
by means of systematic rationalisation,”
he says. The decision was taken prior to
the economic crisis of the past two years
and, in the context of the crisis, has proven
to be the correct one.
Summary
In a production area of just 1.5 x 2.5 metres
the “Mobile Robot Platform RPm” developed
by SYMACON for MOTOMAN robots
unites a wealth of technical and technological
options. It thus ensures maximum
flexibility in the production process.
The modular configuration can be customised
to individual requirements, and the
solution also offers an interesting alternative
to other dedicated solutions in terms
of price.

16
INNOVATION
Delta robot completes the
MOTOMAN product range from YASKAWA
High payload, large workspace and exceptional speed: the new “MPP3” delta robot for demanding picking tasks completes
the MOTOMAN product range from YASKAWA. This new development means that the technological implementation of
entire packaging lines is now possible, for the first time, using exclusively products from this manufacturer – thus offering
all the characteristic advantages of a leading brand.
From the picking of bags, cartons and jars
in the food industry to the handling of wafers
in the assembly of solar panels: the
range of potential applications for the new
MPP3 delta robot is enormous.
Its compact dimensions allow space saving
installation directly above the conveyor
belts. A standard flange supports a
wide range of different grippers. Furthermore,
with protection classification IP 65,
it is easy to clean.
Irrespective of the application specific design,
the flexible delta robot is characterised
by one overriding advantage: it combines
the speed of the delta design with a
high payload capacity and a large radius of
action.
In the spotlight: maximum availability
In this 4-axis robot with a parallel kinematic
system, the fourth axis, the so-called
wrist axis, is significantly stronger than in
comparable models. This enables it to
move payloads of up to 3 kg at an unprecedented
speed: 140 cycles per minute
with a 3 kg payload and 230 cycles per
minute with a 1 kg payload are possible.
The conveyors can be operated at a velocity
of up to 120 m/min. The working
envelope is also very generous. It comprises
a total lift height of 500 mm with a
diameter of 1,300 mm in the cylindrical
upper section of the working envelope
and a diameter of 950 mm in the conical
lower section.
As with all MOTOMAN brand products,
special attention was paid to availability of
the machine during development of the
new delta robot. One precondition for
this are particularly hard wearing parts.
Furthermore, these are designed in such
a way that they can be quickly and easily
exchanged. Given the high mechanical
quality, long maintenance intervals and
short downtime, the availability of the
MOTOMAN robots is approx. 95 percent,
which means maximum production, process
reliability and constant quality in a
day-to-day operation.
Packaging lines from a single source
The performance of the MPP3 is maximised
in conjunction with downstream
packaging robots. As a new member of
the MOTOMAN product family, it can be
ideally combined with other products in
the range to form complete solutions
with seamlessly integrated technology.
The result is complete packaging lines
from a single source: from picking the
product to final preparation of the pallets
for shipping.
One possible practical application: the
delta robot uses its vacuum gripper to pick
up the product in its primary packaging –
e.g. a packet of sweets – and places it at
high speed in a carton or shallow tray. In
a second operation, a 5-axis MOTOMAN
MPK2 robot takes over. With its streamlined
gripper and 400 mm long Z axis, it is
ideal for loading crates and deeper trays.
With a payload capacity of 2 kg, it manages
133 cycles per minute. This complex,
high-speed process is supervised by the
MOTOpick process management software.
This software controls both the integrated
image processing functions and
the tracking of the conveyors. Correct
positioning of the correct product is thus
automatically assured at all times. Moreover,
MOTOpick provides the system
operator with a user-friendly interface
that can be used for the quick and uncomplicated
integration of new patterns.
The remaining packaging process for the
correspondingly pre-grouped components
calls for robots such as the 4-axis MOTO-
MAN MPK50. This robot has a payload
capacity of up to 50 kg and a working radius
of 360°. The MOTOMAN MPL series,
designed for the end of line palletising
operations, comprises the widest range
of 4-axis robots on the market. It covers
payloads from 80 kg to 800 kg and palletising
heights of over 3 meters. Here, once
again, comprehensive software solutions
take care of process control for the entire
palletising cell and up to six conveyors.
Robotic packaging lines such as this offer
distinct advantages over conventional linear
or gravity packers: they are flexible in
operation but are gentle on the products.
Software controlled robots, such as
MOTOMAN robots from YASKAWA, can
be reprogrammed in a few minutes. Production
can thus be adapted to suit any
time at short notice.
Summary
With the newly developed MPP3 delta
robot, YASKAWA has added to its range
of high performance MOTOMAN industrial
robots the component required for
versatile picking applications. This robot
combines the speed of the delta design
with the high payload capacity, large workspace
and process reliability associated
with the name MOTOMAN worldwide.
The new MPP3 delta robot made its
worldwide debut at Interpack in Düsseldorf
from 12 to 18 May.

INNOVATION 17
State-of-the-art
palletising robots
The new DX-series MOTOMAN robots have a whole range of new and improved features, including functions
for order picking, packaging and palletising applications.
YASKAWA presents the innovative, 4-axis
MPL palletising robot series for payloads
from 80 to 800 kg. These dynamic movers
are characterised by extreme acceleration
and enormous axis velocities. At
the same time, they have minimal space
requirements for installation.
The MPL models feature internally routed
supply lines (four air hoses and 22 electric
cables) all the way to the flange mounting,
thus enabling maximum service life of the
dress packages. The MOTOMAN MPL100,
MPL160, MPL300, MPL500 and MPL800
models are also equipped with a hollow
wrist with a diameter of 50 or 60 mm.
Even in the case of larger motions of the
wrist axis, there are thus no freely routed
media packages.
Like all new robot models from MOTO-
MAN, the MPL series is also controlled
using the high performance DX100 controller
and can thus be equipped with all
commonly-used bus systems, e.g. ASI-S.
This bus cable can optionally also be
routed internally through the robot as far
as the flange mounting.
The undisputed strongman of the series
is the MOTOMAN MPL800. This palletising
robot has a payload capacity of 800
kg and a wrist axis torque of 500 kgm²,
thus making it ideally suited to the handling
of particularly heavy workpieces. On
request, the MPL robots can be supplied
with a palletising software package tailored
to the customer’s specific requirements,
either on a PC or directly on the teach
pendant.
The MOTOMAN MPL800
is ideally suited to the
handling of particularly
heavy workpieces.

18 INNOVATION
Plug & Play
robotic welding system
“MotoWeld-SR350”
MOTOMAN is the leader in robotic arc
welding technology and is extending its
scope of supply to offer a complete robotic
welding package with the “MotoWeld-
SR350” power source for the MOTOMAN
MA1900 and MOTOMAN MA1400 robots.
This package is a plug & play solution for air
cooled MIG/MAG welding, which offers
great benefits for cost efficient welding
and is user-friendly and easy to install. As a
customer, you benefit from our extensive
experience in welding applications and the
seamless integration of robot, controller,
power source, cabling, wire feeder and
torch. This welding package is ideal for
compact welding cells, first-time robotic
welding and for those looking for a simple,
but efficient, welding solution.
Key benefits:
• Easy to operate and maintain
• Cost efficient solution
• Complete package from a single supplier
• MotoWeld-SR350 is specifically designed
for robotic welding
Scope of delivery:
• SR350 power source
• Wire feeder: 0-18 m/min.
• Torch neck
• Collision sensor
• Control analogue voltages (2 channels)
• Manual in English
“MotoWeld-SR350”
is a plug & play solution
for gas-cooled
MIG/MAG welding.

TRADE FAIR 19
YASKAWA at MEDTEC Europe 2011
(Landesmesse Stuttgart, 22–24 March 2011, Hall 8, Booth 8-157)
Automation on the advance
in medical technology
YASKAWA exhibited at the MedTec trade fair in Stuttgart for the first time, from 22 to 24 March 2011, at the shared booth
of the VDMA trade association Robotik + Automation. A total success!
During the four days of the MedTec fair,
visitors could witness that YASKAWA,
with its broad product range, is able to
offer suitable robotic automation solutions
for existing and future problems in the
field of medical technology. Since the
medical technology branch is just at the
threshold of a wave of intensive automation,
there was a great deal of interest.
On show was the compact MOTOMAN
MH5 robot which offers maximum performance
despite its minimal space requirements
and low procurement costs.
Areas of application include laboratories
and research facilities where samples
have to be processed and tested.
However, MOTOMAN robots are also
utilised for tasks in the fields of medical
technology and pharmaceuticals outside
the laboratory.
A MOTOMAN MPK2 can be used, for
example, to stack medicines carefully into
cartons. These can then be packed at
high speed onto pallets using a MOTO-
MAN MPK50 or MPL100.
In addition to laboratory work and the
packaging of medicines and other medical
products, robots can also be used in
the field of physiotherapy. YASKAWA has
many years of experience in this area.
Having branched out into the fields of
medical technology and pharmaceuticals
years ago, the many enquiries in this
sector regarding specific tasks show that
YASKAWA has established itself as the
competent automation partner.
YASKAWA at Blechexpo/Schweisstec 2011
(Landesmesse Stuttgart, 06–09 June 2011, Hall 6, Booth 6512)
Fully synchronised for greater
efficiency in the welding process
At this year’s Blechexpo/Schweisstec, YASKAWA focused on multi-robot
technology and solutions relating to the trend topic “jigless welding”.
Seven MOTOMAN robots, coupled together
via a single shared controller,
co-operated in a spectacular show cell.
This featured MotoWeld SR350, a special
Plug & Play solution for air cooled welding.
This kind of “synchromotion” system
which, in practice, can integrate eight fully
synchronised MOTOMAN robots with up
to 72 axes, offers distinct advantages
over individually controlled robots: without
the need for major programming effort, it
enables the synchronised operation, or
parallel motion, of robot and positioner.
Welding and handling processes are
carried out in a single step. The quantity
of fixtures required is greatly reduced.
At the same time, the highly flexible
system guarantees maximum process
reliability.
Two high-speed MOTOMAN VA1400
welding robots also form an integral part
of the exhibited multi-robot system. This
model is one of the world’s first industrial
robots for the arc welding sector with seven
controlled axes. Thanks to its streamlined
design, the flexible 7-axis robot has
extremely high freedom of motion, even
in highly confined workspaces.
At the same time, the robot density in the
manufacturing cells can be considerably
increased.
Furthermore, the VA1400 supports jigless
welding applications: co-operating robots
perform the entire handling and welding
process without the need for positioners
or additional fixture systems.
This enables even more efficient production
processes.
The high-speed, 7-axis
MOTOMAN VA1400
robot was one of the
exhibits that could be
experienced live at
YASKAWA.

20
TRADE FAIR
YASKAWA at interpack
(Düsseldorf, 12–18 May 2011, Hall 16/Booth A45)
Trend topic: Cost efficiency
and process efficiency
At interpack 2011, YASKAWA turned the spotlight on robotic solutions for primary and secondary packaging and palletising.
A particular highlight at the booth was the MOTOMAN MPP3 delta robot, making its worldwide debut at this trade fair.
At interpack 2011, YASKAWA turned the
spotlight on robotic-solutions for primary
and secondary packaging and palletizing.
A particular highlight at the booth was the
MOTOMAN MPP3 delta robot, making its
worldwide debut at the trade fair.
The new development performs versatile
picking tasks at the start of the packaging
chain.
The 4-axis robot with parallel kinematic
system combines the speed of the delta
design with a high payload capacity and a
large working range.
Also a topic at the booth: the current,
steadily increasing demands from industry
for greater cost and process efficiency.
YASKAWA is responding to this trend with
a wide ranging product portfolio and integrated
total solutions: MOTOMAN is
enabling machine and system builders in
the packaging industry to cover the entire
PPP process with high quality products from
a single source.
The product range, designed with a view to
minimal space requirements and maximum
speed, enables the conception of extremely
compact complete solutions. The result:
Standardised implementation of complete packaging lines with the MPP3 and MPK2.
greater system profitability due to reduced
space requirements. Furthermore, MOTO-
MAN robots with the “Green energy function”
are equipped with energy-saving technology.
A picking-packing cell at the booth illustrated
how such topical robotic solutions
can be implemented: the MPP3 delta robot
and an MPK2 robot work together in the
show cell. A camera, the MOTOpick user
interface and a complex conveyor belt
monitoring system complete the solution.
With this so-called “double conveyer
function”, products arrive on one belt, are
detected by a camera, are shared between
both robots through the MOTOpick software
and deposited on a second conveyor.
The cell thus emphasises both the combination
of software with camera and robot,
and also the performance of the robots and
the overall package.
In addition YASKAWA presented the performance
of the fast MPK50 packaging
robot in an application palletising boxes at
interpack. Furthermore, visitors to the
trade fair could witness just how easy and
user-friendly operation of the DX controller
really is by programming an MH5 robot.
Impressions of the trade fair booth
at interpack 2011.

TRADE FAIR 21
Interest in the new MPP3 delta robot and in picking and packing with the MPK50.
Trade visitors were able to hear explanations about the MH5 and had the opportunity to try programming it.
Servo and inverter drives from the Drives & Motion Division.

22 TRADE FAIR
YASKAWA looks back on a effectively interpack trade fair
(Düsseldorf, 12–18 May 2011, Hall 16/Booth A45)
“Rapid development in
the packaging market”
YASKAWA looks back on a effectively interpack premiere: the company, which manufactures MOTOMAN-brand industrial
robots, exhibited at the international trade fair for the packaging industry for the first time.
Innovation highlight: the MOTOMAN MPP3 delta robot.
“In the field of robotics, we now cover the
entire product spectrum for the packaging
market,” says Alexander Steiger, Sales Manager
for Robots & Products at YASKAWA,
retrospectively explaining the company’s
participation in this particular trade fair.
“Our presence at interpack was the logical
consequence.”
Innovation at the trade fair:
MPP3 delta robot
The particular highlight at the company’s
booth was the new MOTOMAN MPP3
delta robot which made its live debut here.
“With the MPP3, it was not just another
trade fair innovation that we were presenting,
but the world’s fastest robot in operation”,
adds Steiger.
Another topic at the interpack booth was
overall solutions from both YASKAWA
divisions – Robotics and Drives & Motion.
“We were confronted with a number of
specific applications in the fields of biscuit,
production and packaging, which spanned
both divisions,” explains Steiger. “This
opened up new approaches for new developments.”
Potential
According to observations made by YAS-
KAWA, the potential for robotic packaging
solutions remains far from fully exploited.
This view has been confirmed by many
trade fair discussions with both domestic
and international customers. “Many tasks
in this industry are still performed manually.
They can be implemented far more
efficiently with really simple automation
solutions that have a fast return on investment,”
asserts Alexander Steiger.
Summary
“Interpack 2011 was a complete success
for us,” concludes Steiger. “We had a large
stream of visitors with a high proportion of
them coming from abroad. It is thus not
only our workforce here in Germany that
profits from the positive response, but also
our colleagues in Europe and overseas. We
returned home with good results: on the
one hand, a set of high-quality contacts,
and on the other hand, confirmation that
we have developed the ideal robot for the
packaging market.”
The MOTOMAN MPP3 delta robot.

EVENT
23
Technology show at YASKAWA Europe a complete success
Focus on the aerospace sector
At a technology show in February 2011, robot manufacturer YASKAWA underscored the fact that the company’s expansion
strategy does not shy away from branching out into new markets. The aerospace industry is one sub-sector with tricky
applications for which YASKAWA already offers suitable solutions.
The slogan chosen for the event, “Go
Robotics”, could not have been more apt.
Attended by more than 100 participants,
primarily from the aerospace industry, but
also from the automotive industry, particular
interest at the event was focused on
automation solutions for tasks that were
previously difficult to automate or had not
been automated at all. In high-quality presentations,
the speakers presented pioneering
solutions and promising technologies
for precisely this kind of application.
There are numerous reasons for the fact
that relatively many tasks in the aerospace
sector are still carried out manually and
that automation is only slowly making inroads.
Alexander Steiger, Sales Manager for
Robots & Products at YASKAWA Europe
GmbH, attributes this, in part, to the fact
that there is significantly less demand for
robots than in the automotive industry,
which makes many manufacturers reluctant
to commit themselves too heavily
in the aerospace sector. “A second, even
greater problem, is often the programming
for aerospace applications, which are
doubtless highly interesting. These are
dominated by free-form surfaces which
require extremely complex programming
when using conventional methods,” claims
Steiger. In partnership with software speialist
Cenit, YASKAWA offers integrated,
automated processes that enable the manufacture
of complex components directly
from the computer, faster and more costeffectively
than ever before.
From theory to practice
In his presentation on optimized offline programming
as a prerequisite for cost-effective
automation, Dipl. Ing. Nikolai D’Agostino,
from Cenit AG, explained what such processes
and solutions might look like in
practice. D’Agostino showed how systematic
process orientation and integration
into the industry-standard CATIA V5 system
can result in considerable simplification
and integrated data processing. With
open system architecture, the offline programming
of a wide range of handling and
machining processes can be implemented
without major effort.
Alexander Steiger, Head of Robots & Products.
Later in the event, the trade visitors had
the opportunity to see for themselves the
practical advantages of the sketched solutions
implemented in the exhibits. Alexander
Steiger had the following to say on the
matter: “Even industry insiders were surprised
at just how easy MOTOMAN robots
are to program thanks to their DX100 controller
in conjunction with the superior
software solution from Cenit AG. Thanks
to Cenit, the offline programming of highly
complex 3D paths is quicker and easier
than ever before. The combination of
MOTOMAN robots and Cenit software is
a high-performance process solution that
is predestined for complicated applications
in the aerospace sector and without
which certain tasks would simply not be
possible.”
Versatile range of potential
applications for robots
At YASKAWA, typical fields of activity for
robots in the aerospace industry include
deburring, hemming, stitching, riveting,
waterjet cutting and non-destructive testing,
just to name the most important
examples. Given the increasing use of hightech
materials in aircraft construction, such
as glass fiber-reinforced plastic, the need
for automation is increasing accordingly.
This is opening up a whole new range of
interesting fields of application for robots.
YASKAWA’s market analyses were confirmed
by the great interest of the visitors
from the aerospace sector in the automation
of innovative manufacturing processes.
“The best part,” according to Steiger, “is
that YASKAWA, together with Cenit AG, is
already in a position to offer turnkey and
process-reliable solutions for the automation
requirements that are being created.”
Additional advantage: the new solutions
for the new markets also benefit from the
decades of experience of the YASKAWA
(formerly MOTOMAN) team in conventional
systems engineering and from the
expertise acquired from thousands of
completed projects. This combination of
traditional systems engineering know-how
and the new possibilities offered by offline
programming is jump-starting the automation
of complex processes in the aerospace
industry – in accordance with the
slogan “Go Robotics”.
Photo: Ralf Högel
Forthcoming trade fairs
Motek 2011
Landesmesse Stuttgart
10 to 13 October 2011
Hall 7 / Booth 7205
Fakuma 2011
Friedrichshafen
18 to 22 October 2011
Hall A7 / Booth 7208
SPS/IPC/DRIVES
Trade fair & conference
Nuremberg
22 to 24 November 2011
Hall 2 / Booth 131
Automatica 2012
5th international trade fair
for automation and mechatronics
New Munich Trade Fair Centre
22 to 25 May 2012
www.automatica-munich.com

0
VORWORT • INHALT
MOTOMAN near to you
YASKAWA Electric Corporation
JP
2-1, Kurosaki-shiroishi
Yahatanishi-ku
Kitakyushu-shi 806-0004
+093-645-8801
YASKAWA Group
A YASKAWA Austria
Schwechat/Wien +43(0)1-707-9324-15
CZ YASKAWA Czech s.r.o.
Rudná u Prahy +420-257-941-718
D YASKAWA Europe GmbH
Robotics Division
Allershausen +49-8166-90-0
YASKAWA Europe GmbH
Headquarter
Eschborn +49-6196-77725-0
E YASKAWA Ibérica S.L.
Sant Bol de Llobregat +34-93-6303478
F YASKAWA France SARL
Saint-Aignan-de-Grand-Lieu
+33-2-40131919
FIN YASKAWA Finland Oy
Turku +358-(0)-403000600
GB YASKAWA UK Ltd.
Banbury +44-1295-272755
I YASKAWA Italia s.r.l.
Torino +39-011-9005833
IL YASKAWA Europe Technology Ltd.
Rosh Ha’ayin +972-3-9004114
NL YASKAWA Benelux B.V.
EB Son +31-40-2895500
P YASKAWA Ibérica S.L.
Aveiro +351-234-943900
RUS YASKAWA Nordic AB
Moskva +46-480-417-800
SE YASKAWA Nordic AB
Torsås +46-480-417-800
SI YASKAWA Slovenia
Ribnica +386-1-8372-410
Distributors
BG Kammarton Bulgaria Ltd.
Sofia +359-02-926-6060
CH Messer Eutectic Castolin Switzerland S.A.
Dällikon +41-44-847-17-17
DK Robotcenter Danmark A/S
Løsning +45-7022-2477
EE RKR Seadmed OÜ
Tallinn/Estonia +372 68 35 235
GR Gizelis Robotics
Nea Kifissia +30-2106251455
H Flexman Robotics Kft
Budapest +36-30-9510065
Rehm Hegesztéstechnika Kft
Budapest +36-53-380-078
N Optimove as
Lierstranda +47-32240600
PL Integrator RHC Sp. z o.o.
Toru n +48-56-6519710
TR Teknodrom Robotik
Otomasyon San. Tic. Ltd. pti
Gebze/Kocaeli +90-262-678-88-18
ZA Robotic Systems SA PTY Ltd
Johannesburg +27-11-6083182
Headquarters
Robotics
Division
YASKAWA Europe GmbH
Kammerfeldstraße 1
85391 Allershausen
Germany
Fon 0049-81 66-90-0
Fax 0049-81 66-90-103
YASKAWA Academy and
sales office Frankfurt
YASKAWA Europe GmbH
Robotics Division
Hauptstraße 185
65760 Eschborn
Germany
Fon 0049-61 96-777 25-0
Fax 0049-61 96-777 25-39
www.yaskawa.eu.com
robotics@yaskawa.eu.com