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RoboCut 6 Axis Robotic Waterjet / Saw (SawJet) Cutting System

Frequently Asked Questions 

Robots & The Stone Industry

RoboCut is the stone industry’s only high-production dual-table waterjet/saw robot. Integrating both a high-pressure waterjet and 20HP direct-drive saw allows RoboCut to produce a finished cut product and was developed around the idea that not everything in this industry has to be difficult. By utilizing a foundry grade KUKA Robot that is not only dust and waterproof  and has a 10,000 hour maintenance cycle, USG Robotics has taken the “Machine Operator” out of the equation and replaced it with the “Stone Fabricator” mentality through the elimination of thousands of moving parts, various mechanical problems, and machine down-time. This is done while at the same time increasing production by positioning the robot in-between its two tables.

 KUKA’s foundry grade robots are designed to withstand extreme temperatures, water and debris. By bringing these robots to the stone industry, the possibility of water and dust affecting the machine, in any way, has been eliminated. All of the mechanical parts are within the sealed and pressurized robot “shell” giving it an International Protection Rating of 6/7. There are no bellows, no bearings to spray down, none of the typical maintenance seen with conventional bridge-style machines. The maintenance that is involved with RoboCut is simply the upkeep of the waterjet system and purchasing standard consumables like saw blades, nozzles, garnet, etc.. There is, however, a maintenance cycle, but it is only required after 10,000 hours of operation (approximately 10 years of daily 8 hour shifts), and it is just a simple oil change. 

Also, because of the way KUKA Robots interact with computers, USG Robotics is able to offer timely and unbeatable support for any technical issues that may arise. Although it is extremely rare that RoboCut would not operate properly, if this should happen, there is usually nothing to wrench and no parts to order, so there is no reason to incur the cost of sending a technician. The USG Robotics technician can simply login via the internet, read the error code that the robot provides, and then diagnose and resolve the issue within hours, instead of days. This, in turn, gets the robot back to what it does best: cutting stone. 

In addition, by placing the robot in the middle of two tables, RoboCut provides the smallest footprint of a waterjet/saw while maintaining the highest production output capabilities. Without a bridge to interfere and no distance to travel, operators are given the ability to unload and load material in advance and setup files for the open table. Once RoboCut finishes cutting one table, it takes only 10 seconds to transition to the other table. The operator can then unload the pieces that were just cut and begin the setup of the next file, making the machine run non-stop, all day. And with both tables within reach of the robot arm, there are no problems with accuracy. The robot does not have to travel at all, let alone the 12 feet or more to reach the beginning of its second table, which is seen most commonly in bride-style machines. Instead, RoboCut simply turns on its axis.

Features & Specifications:

 

RoboCut & Software

RoboCut runs software that is very different than most. By utilizing the industry’s first photographic alignment system (RoboEyes) and control software that requires no programming (RoboCut Live), USG Robotics has simplified the file setup process. Combined with VeinMatch (Digital Layout Software) and Virtual Inventory Management (Online Photographic Inventory Database), RoboCut offers everything a stone fabricator needs.

With RoboCut, file setup is easy:

Positioning Material - The first step is to load the material on the table. Typically, material must be placed in a specific location through the use of markers or lasers. With USG Robotics’ RoboEyes photo alignment software, material is placed anywhere on the cutting table and a picture is taken. RoboEyes then calibrates the high-definition photograph and loads it directly into the RoboCut Live control software. Here, the image can be zoomed in or out to see its entire scope.

DXF Programming - After loading the picture, a DXF file is opened directly into the RoboCut Live software. The software will automatically assign waterjet and saw tool-paths, lead-ins and lead-outs. It then assigns the waterjet to finish a saw cut so that the lead-ins and lead-outs do not affect adjacent pieces. This software also has the ability to adjust the waterjet kerf based on the piece’s assignment as a “part” or a “hole.”  So if a saw path is finished by the waterjet for inside corners, radius outside corners, sink holes, etc., it will follow the desired edge of the piece and not travel down the center of the saw path. This removes the excess material and eliminates the extra work required when the piece is taken to polish. All of these automatic features also have the ability to be adjusted manually by the operator.

After loading the DXF file, pieces can be moved into position over the image of the material. This is done through simple functions such as “move,” “rotate,” the creation of blocks, and “snap” features that allow pieces to be positioned properly or have two pieces cut with one pass. Adjustments can be made to the tool paths if necessary. They can be done manually or by using tools like “Lead-In (Or Lead-out) With Water” where a saw path will stop short of the edge of its path and the waterjet will finish the cut, or “Change Tool” so that saw paths can be changed to waterjet and vice versa. The ordering of cuts can also be done automatically or manually, and the visibility of waterjet and saw paths can be turned on and off to make the process simpler.

VeinMatch - Once the pieces have been moved into place, operators can preview the final placement of the shapes through VeinMatch. This will allow them to see the area of the image encompassed by the pieces in a separate window. This will show them the final look of the job to verify that all pieces flow well together, especially for any areas with seams. If the operator is satisfied with the positioning he can then send the file to RoboCut and begin cutting.

Off-Site Setup - All of this can be done right at the machine, but USG Robotics also provides a RoboCut Drafter program that can be installed on an off-site computer. This separate program will allow drafters or CAD departments to setup files in advance for RoboCut. This saves time by allowing the operator to simply open the file and begin cutting. This is done with the use of calibrated slab images taken through the VeinMatch or Virtual Inventory Management software.

Features

  • Accepts files directly from all major CAD programs
  • Automatically sets saw and waterjet paths to optimize cutting efficiency
  • Automatically sets lead locations that will not cross over other cut paths
  • Various user levels give full functionality to drafters and CAD departments
  • User-friendly interface runs on Windows Platform
  • Snap function to create one tool path for two piees
  • Easy-to-use tool functions
  • Includes waterjet cut speeds, accelerations, and slowdowns for varying stone types
  • Automatic waterjet lead-ins and lead-outs for inside corners or tightly nested pieces
  • Outputs directly in KRL, the language of the robot, no g-codes or post-processors needed
  • Integrates with VIM Virtual Inventory Management and VeinMatch for cutting without any setup at the robot
  • Saw current feedback
  • Warnings for incorrect file setup and overlapping shapes