A recent video showcases a robotic cell featuring a KUKA KR30-3 mounted on a linear rail (track) and paired with two rotary positioners as part of an advanced handling or welding solution. This configuration is gaining ground as a flexible alternative for production lines, though it is not without challenges. Eurobots, as a provider of guaranteed robotic solutions, promotes these integrations to clients seeking to modernize their industrial facilities.
Before addressing the challenges and benefits, it is helpful to review the basic features of the robot:
The KR30-3 is a six-axis robot suitable for medium loads (~30 kg). Its reach is about 2033 mm.
Declared repeatability: ± 0.06 mm according to official data.
It can be used in various mounting positions (floor, ceiling, wall) and variants for demanding environments (foundry, harsh environments).
With these capabilities, the KR30-3 is ideal for applications such as handling, welding, light assembly, adhesive application, inspection, in sectors like automotive, machinery, metal structures, etc.
Classic production lines—with fixed stations, fixed part movements, or manipulators with limited travel—face several obstacles impacting their efficiency, quality, or scalability:
- Rigidity in layout: When processes are designed rigidly, any change in part, size, or geometry requires redesigning the entire line, making future modifications expensive.
- Reach or positioning limitations: A fixed robot might not reach complicated areas of the part, requiring additional stations or collateral manipulators, which increases structural costs.
- Bottlenecks due to idle times: In lines where some processes take longer than others, robots can be left idle or the line can get “stuck” if cycles are not perfectly synchronized.
- Part variability / frequent product changes: If the factory handles different models or versions, changing the loading position, orientation, or sequence can require significant time for reloading or reprogramming.
- High costs in auxiliary equipment: Many processes require carts, conveyors, intermediate rotators, special manipulators, which increase the total equipment and maintenance cost.
- Accessibility and maintenance of the installation: When robots are in fixed positions or complex enclosures, maintenance interventions, access for calibrations, or repairs can be difficult.
Integrating the robot on a linear rail (track) together with rotary positioners offers greater flexibility, extended reach, space optimization, and operational improvements. Here are the main benefits and impacts:
- Effective extension of reach and reduction of stations: by mounting the KR30-3 on a linear rail, it can move longitudinally along the cell. This means a single robotic unit can service multiple work points, moving along the rail axis. The rotary positioners allow the part to rotate around axes to optimize tool access without having to reposition the robot each time. As a whole, this reduces the need to duplicate fixed robots or independent stations, achieving greater functional density of the space.
- Increased flexibility and adaptability to change: When products change, it is enough to reprogram the robot’s path on the rail or adjust the positioners, without major mechanical changes. This allows for a more adaptable line, ideal for variable batches or customized production.
- Better timing synchronization and load balancing: The robot can move to where a part is available, reducing idle times. The rotary positioners can also operate in parallel while the robot performs another movement, helping minimize waits and improve utilization rates.
- Lower investment in auxiliary manipulators: With a rail and rotators, there is less need for other intermediate conveyors or secondary robots that only perform rotation or displacement functions. The integrated solution simplifies cell design and reduces costs for additional equipment, infrastructure, cabling, and control.
- Improved maintenance and accessibility: The robot on the rail can move to accessible areas for maintenance, calibration, or technical intervention without the need for complex disassembly. In addition, the rotators can be positioned in more accessible spots for inspection or replacement.
- More consistent process quality: Having a single unit ensures repeatability and continuous movements, reducing the risk of misalignments or errors between stations. Also, the rotary positioners keep the tool optimally oriented with respect to the part, improving quality in critical operations such as welding, adhesive application, or light machining.
Although URT does not carry out the integration directly, as a provider of robotic solutions it guarantees that the components (robot + rail + positioners + control) meet the required specifications and offers technical support and advice to the end customer for implementation.
To ensure the solution’s effectiveness, it is recommended to:
- Conduct a 3D study of the cell with simulation of the robot’s movements on the rail and rotations of the positioners, detecting collisions, interference zones, and idle times.
- Size the rail (length, load, rigidity) with sufficient margin for the most extreme movements.
- Ensure synchronized control between robot, rail, and positioners using a master controller or PLC that orchestrates the movement phases.
- Provide flexible cables and conduits for the robot’s supply (power, pneumatic, signal wiring) along the rail.
- Consider safety (barriers, sensors, light scanners) when allowing the robot to move along the rail.
- Carry out periodic calibration of the system, combining rail position + rotator position + robot position to maintain accuracy.
The configuration shown in the video—a KUKA KR30-3 mounted on a rail with two rotary positioners—illustrates an advanced automation approach that helps overcome several major challenges of production lines: rigid designs, reach limitations, idle times, and high auxiliary costs.
By offering this guaranteed solution, URT can empower industrial companies seeking to modernize their processes with a more agile and efficient architecture. For factories managing product variability, frequent model changes, or sectors demanding space optimization and fine synchronization, this integration represents a path toward smarter, more compact, and competitive production lines.
At URT, we recognise the value this robot brings to highly demanding sectors such as electronics, and we offer solutions that enable our customers to integrate ABB technology into their production lines to achieve new levels of efficiency and competitiveness.