German assembly line manufacturer and automation specialist KUKA Systems will be exhibiting at a stand some 170 m2 in size at this year’s BlechExpo trade fair, to be held in Stuttgart from 1 to 4 December. At its stand, number 6103 in hall 6, the company will present a variety of core elements from its press line and press automation portfolio, from the new KUKA Cobra development through the very latest Transpressor generation to innovative, web-based control software. KUKA CobraLightning quick and with plenty of bite - that’s the KUKA Cobra. In this new press-to-press robot the gripper can be swivelled horizontally, delivering a greater clearance and improved flexibility in the press. The interference contour to the press tool is minimised by a combined linear axis with swivel drive. The KUKA Cobra allows the maximum output to be increased to up to 18 pieces per minute. This is achieved by superimposing the movements of the axes while at the same time sharply reducing the masses being moved, ensuring linear, flexible component transport in freely programmable movement curves from press to press. Press gaps can be reduced down to 5.2 metres, which brings savings in buildings costs. Full flexibility in tool changes is retained through the use of a tried-and-tested kinematic system. Components including grippers up to 100 kilograms in weight can be picked up. A standardised adapter plate allows the transfer unit to be fitted with any standard tooling. The KUKA Cobra will be presented as a current application at this year’s BlechExpo.KUKA TranspressorTM 100 AThe KUKA Transpressor 100 A is a new addition to the TranspressorTM product family. To minimise interference contours on plunging into the press, the arm of the press-to-press robot is connected linearly to the robot hand by means of an angled adapter. This allows the output to be increased compared with previous models through improved locking values. The TranspressorTM 100 A really comes into its own when large components such as side panels need to be produced on a press line. The KUKA Transpressor 100 A thus complements the Transpressor portfolio. KUKA Transpressors offer useful loads of 50 to 100 kilograms and cover press gaps of up to 8.50 metres. KUKA Systems will be presenting this new technology in Stuttgart.Software for press automationThe intelligent software solutions from KUKA Systems ensure greater output, higher availability and full transparency of current production at all times in the press line.The PressTec software family is based on modular, functionalised units, allowing it to be scaled to meet any requirement in press plant automation and information.KUKA line control with KS PressTec V5The KUKA base module coordinates and controls the sequence of movements of the presses and robots, ensuring optimised output as well as collision-free cooperation between the systems. The new version V5 delivers further reductions in press loading and unloading times thanks to forward planning robot synchronisation under the press. The integrated LogicAnalyzer saves all data during operation, ensuring end-to-end diagnosis capability. Current standards such as automatic press starts with continuous optimisation, time-optimised press unloading and optimised component pick-up, have been further improved. The interface to the master control has been expanded with analysis data for preventive maintenance and an intelligent fault detection system.KUKA line monitoring with KS PressMaster V5This modular software allows the whole line to be visualised. PressMaster also provides component program management, fault analysis and operator guidance. The entire documentation of the line is integrated, minimising restart phases in the event of a problem. Modularisation allows additional modules to be added as required. Modules for cycle time optimisation, data archiving and preventive maintenance programs can also be obtained. The new KUKA ProductivityControl software module includes an energy monitoring function as well as a detailed reporting system. All modules can be dynamically reloaded into the KS PressMaster V5, even at a later stage. This makes it easy to respond to rising information requirements in the future. The KS PressMaster V5 is a key step towards future-proofing in the press plant.ProfiNet/ ProfiNet-Safe control conceptThis new bus system reduces the diversity of systems in conventional press lines currently used on the market to a single, Ethernet-based system. The direct communication of the transfer system delivers a further optimisation in the line cycle time. Other benefits include the shortening of assembly and commissioning times through prefabricated, plug-and-play components, component minimisation and high availability as well as process reliability through Ethernet, optimum diagnosis alongside complete consistency and, not least, faster cycle times. The customer can also be confident of forward compatibility and safety of investment through the use of the corresponding communications systems.