KAWASAKI Foam Milling Cell (Larger Volume)

1.0 System Overview & Purpose

The system is a fully integrated robotic machining cell designed for the high-precision, flexible milling of wood components. It combines a heavy-payload industrial robot with a high-speed spindle and auxiliary systems to automate complex milling, carving, and shaping operations, enabling unattended or minimally attended production cycles.

2.0 Core Robotic System

2.1 Robot Manipulator

• Model: KAWASAKI RS020N

• Reach: 1725 mm 

• Payload Capacity: 20 kg

• Number of Axes: 6

• Mounting: Floor-mounted

• Protection Class: Standard (dust protection recommended for wood environment)

• Repeatability: ±0.04 mm

2.2 Robot Controller

• Model: KAWASAKI E-series Controller

• Control Cabinet: Integrated into main electrical cabinet

• Software: KAWASAKI AS Language / Optional graphical interface.

• Programming Device: KAWASAKI Teaching Pendant (specific model for E-controller)

2.3 External Rotary Axis

• Component: KAWASAKI External Axis Kit

• Servo Motor: KAWASAKI-compatible Servo Motor, 2.0 KW.

• Driven Device: Heavy-Duty Rotary Table

• Control: Fully integrated into the Kawasaki controller as an auxiliary axis.

3.0 Machining System

3.1 Spindle Unit

• Type: High-Frequency, Air-Cooled Spindle

• Power: 4 KW (Continuous)

• Speed: 24,000 RPM

• Cooling: Integrated water circuit, connected to external heat exchanger.

• Tool Interface: HSK-63F

• Lubrication: Grease-lubricated, maintenance-free bearings.

3.2 Spindle Drive & Control

• Variable Frequency Drive (VFD): 4 KW capacity.

• Function: Provides precise speed control (0-24,000 RPM) for the spindle. 

• Integration: Mounted in the main electrical cabinet.

3.3 Tool Management System

• Tool Holder: HSK-63F, balanced for high-speed operation.

• Tool Set: Single tool for foam milling

4.0 Workholding & Positioning

4.1 Rotary Table

• Type: Servo-driven, position-controlled rotary axis.

• Payload Capacity: 500 kg (including fixture and workpiece)

• Drive: Connected to the KAWASAKI 2.0 KW external servo motor.

• Function: Integrated as an auxiliary robot axis, allowing simultaneous machining or precise indexing.

• Fixture Interface: Customizable mounting plate 

5.0 Cell Infrastructure & Enclosures

5.1 Cell Base & Structure

• Base Frame: Welded metallic base, providing a rigid and level foundation for the robot and rotary table.

6.0 Wiring & Cabling

• Internal & External Wiring: All necessary power, signal, and feedback cables for a complete turn-key installation, including robot-to-cabinet, spindle-to-VFD, and all field device connections. Cables must be specified for Kawasaki compatibility.

7.0 Utilities & Site Requirements

• Electrical Supply: 230VAC, 1-phase + Neutral + Earth, 50/60Hz. 

• Floor Load: Must support concentrated load of cell (robot, table, workpiece > 2500kg).

• Environment: Recommended temperature 10-40°C. 

8.0 Deliverables

1. Fully assembled and integrated robotic milling cell.

2. Complete electrical schematic diagrams.

3. Software backup with basic milling programs and tool data (using Kawasaki AS language).

4. Operational and safety training for end-user personnel.

5. Full documentation pack (mechanical drawings, manuals, certificates).