Vol.02 LCMR200
CHALLENGERS OF MONOZUKURI
Story of New Model Development
CHALLENGERS OF
MONOZUKURI
Story of New Model Development
Vol.02 LCMR200
RELENTLESS PURSUIT OF QUALITY
WITH MANUFACTURING, SALES AND
TECHNOLOGY INTEGRATED
The conveyance system LCMR200 has gone into full-scale operation. We interviewed the development team members of the Robotics Business Unit. This team worked on the further leap forward of the Linear Conveyor Modules that are taking a strong lead in the Japanese market.
Do you know that Yamaha’s industrial robots are widely used for production equipment in various industries? Among them, Yamaha’s Linear Conveyor Modules, which were commercialized for the first time in Japan in 2013, are serving as a pioneer in the market. This conveyance system is characterized by its modular structure and high-speed direct drive using linear motors. Unlike conventional belt conveyors or roller conveyors, this system not just carries objects, but also works together with robots that perform specific tasks such as assembly, enabling more efficient manufacturing and operation. This product is now drawing attention as next-generation conveyance equipment.The latest model of its kind is LCMR200. As the successor to the LCM-X, LCMR200 was released in May 2020, which eliminates waste in manufacturing processes and achieves advanced conveyance automation. It debuted as a new-generation Linear Conveyor Module with improved usability, durability, and other features.
We interviewed the development team members from the FA Product Engineering Division, Engineering Section, Robotics Business Unit, Solution Business Operations, who are: project leader KATAYAMA Manabu and KOUDA Hideaki from Mechatronics Development Group of the Unit; MUKAI Masayuki from Electronics System Development Group; and AOKI Shunsuke from Controlling Software Development Group.
YAMAHA’S UNIQUE CONVEYANCE SYSTEM USING ROBOT TECHNOLOGY REALIZES A FLEXIBLE AND EFFICIENT PRODUCTION LINE
The Linear Conveyor Modules that Yamaha has developed are a system that has built-in linear motors in the module body, which also acts as a rail, and directly drives the sliders on which objects such as parts are placed. To respond to today’s demand for the manufacturing of variable types and quantities of products, Yamaha has developed the Linear Conveyor Modules as a conveyance system that realizes an efficient and highly profitable production line, which includes a more flexible production system and reduction of wasted time between processes.
Its performance has evolved beyond comparison with conventional conveyors. For example, speed and acceleration of the conveyer can be set individually and slider positioning stoppers are no longer required, enabling smooth stop-and-go movement. It is also possible to perform a task on the sliders. The modularization not just makes it easy to change the production line, but also contributes to saving space. This new model has a variety of features and functions that eliminate waste and increase efficiency.
“While most conveyance system manufacturers offer their products focusing on control technology, Yamaha has great advantages in mechatronics, which is robot technology, as well as motors and their control. These acquired advantages eventually lead to the marketability of Yamaha products that have good compatibility with assembly robots,” says Katayama. This new system is indeed a robot that not only carries and delivers objects, but also works together with other tasks such as assembly.
That is why this system can be called a pioneer as mentioned above.
There are almost no competitors in this field, so it’s not too much to say that Yamaha is running alone in the market. Behind such a market situation, the development team is committed to applying for patents, as each business unit of Yamaha does. Mukai says, “In addition to its uniqueness, this new model’s patents may keep other companies from developing similar products.” The development team has acquired a number of patents in each development project. Still, it seems that their superiors are demanding more patents to be obtained.
Robotics Business Unit, Solution Business Operations
TO KEEP CUSTOMERS’ PRODUCTION EQUIPMENT RUNNING, THE TEAM SOMETIMES WENT OUT TO THE CUSTOMERS WITH TOOLS IN THEIR HANDS TO FIX PROBLEMS
The LCMR200 is the latest model of such market-leading Linear Conveyor Modules. This model was launched as a brushed-up model of the previous model LCM-X, which was released in 2016, while inheriting the high precision and narrow pitch features of the predecessor model. Even though being a brushed-up model, the LCMR200 is an extensively revised model, as Kouda says, “It looks better than a remaster, but not so much revised as a remake.”
“The LCM-X is a completed model, but there were cases where it could not fully demonstrate its original performance depending on the environment in the factory and how the customer used it,” says Katayama. The rigidity, for example, once caused some trouble. Previous models adopted a bridge pier type structure for their modules, but pressure could be applied to the sliders at some work sites, and depending on the platform structure provided by customers, small deflection was generated, eventually leading to several problems.
In other cases, depending on the work site environment, foreign substances entered through the small holes on the top cover of the modules for cooling the internal motors, causing the system to malfunction, or noise through the small holes had an adverse effect on the machine operation. The development team faced a number of such challenges. “We found it difficult to have customers use the LCM-X in the same manner as we instructed. This model also demanded high levels of machine handling to our customers,” says Mukai. While having a potential of providing an advanced work environment, the LCM-X allowed only limited users to get such high performance out of it.
If customers’ equipment doesn’t work, it is inevitable that it will cause a great deal of inconvenience to the customers. Thus the development team often visited their customers to give them full support until problems were corrected. “When a problem arose, we rushed to the customer with our tools in our hands. In some cases, we even modified the platform design to improve accuracy. Sometimes we received a severe reprimand from customers, but by talking directly with them, it was an opportunity for us to consider what should be done. At the same time, it was also a good chance to build close relationship with our customers,” says Kouda.
Based on what they learned from such experiences, they started working on the development of a new model that can be easily used anywhere with peace of mind while taking advantage of the excellent performance of the LCM-X. Under Katayama’s determination “Let’s do everything we have learned from the LCM-X,” the team members decided to work together in the development project.
Engineering Section, Robotics Business Unit, Solution Business Operations
CRITICAL COMPONENTS WERE SELF-MANUFACTURED AFTER NUMEROUS TESTS OF THE PRODUCT WITH UNCOMPROMISING PURSUIT OF TECHNOLOGY AND QUALITY
The biggest modification from the previous model was made to the installation structure of the linear conveyor. The bridge pier structure of the LCM-X was changed to a new installation method, in which the linear conveyor was directly attached to the platform. In addition, the sizes of the linear guides and the guide blocks of the sliders were increased to ensure high strength and suppress thermal expansion. As a result, overall rigidity was increased and durability against press force such as press fitting was also enhanced. Furthermore, electrical components were sealed to prevent contamination by foreign substances and the cooling method was also changed so that heat can escape to the platform. The development team reviewed all the problems surfaced one by one. They didn’t forget to take on new challenges. “To achieve high accuracy, we changed the sensor configurations and developed a new magnetic scale in-house. We also manufactured a magnetizing device for adding scale markings by ourselves.
While making these parts in-house, we had to be attentive to the yield in production, which I think was the hardest part in this project,” says Kouda. Mukai also says, “It was our first experience in parts development that we had to pay attention to the yield.” Their choice of in-house development and manufacturing rather than relying on outsourcing demonstrates their commitment to the accuracy of their own products. In fact, the new model has higher positioning accuracy than ever before. As we heard more about their development story in the interview, we found that they had given such thorough revamping to the new model that we could say it was a remake.
Machine control was also advanced significantly. Both the LCM-X and LCMR200 are controlled by the YHX, a dedicated controller that can manage up to 64 sliders collectively. But when the LCM-X was first released, it was necessary for customers to write a control program by themselves.
“Some customers had difficulty writing a control program, so our staff members in charge of the software frequently visited the customers’ work sites,” says Aoki.
Based on such experience, they pursued user-friendliness of their product and, prior to the launch of the LCMR200, finally developed the software called Standard Profile that eliminates the need for customers to write a control program, so that customers can construct their automated equipment more easily.
By having the system interpret the commands sent from the PLC (Programmable Logic Controller) on the upper level of the system, the team made it possible to directly control the LCM-X and LCMR200 from the PLC.
Engineering Section, Robotics Business Unit, Solution Business Operations
CRIUNDER THE COVID-19 STATE OF EMERGENCY DECLARED IMMEDIATELY BEFORE THE DEBUT OF THE PRODUCT, THEY OVERCAME MANY DIFFICULTIES WITH THE POWER OF MANUFACTURING, SALES AND TECHNOLOGY INTEGRATION
The LCMR200 was brushed up so much that we cannot introduce everything here, but the actual development period was just about one year. Although the project started after some of the problems and solutions of the LCM-X had been identified as mentioned above, this development schedule was too tight for the team members, who had the desire to produce an uncompromising product with high quality. It was easily predicted that they could fail to meet the deadline for the project if a single stumbling occurred. How did they manage to tackle this development project?
“In the past, software, mechanics and electronics groups had been individually engaged in development projects. But we decided to set up weekly meetings to share problems and information as well as to enhance a sense of togetherness as a team. We invited not just the development members, but also those from the sales, quality assurance, service and production departments and showed them what we had done and what we had in mind,” says Katayama.“As a result, no member or no department carried the burden by himself or by itself, which eventually enabled us to examine problems through various approaches and reduce do-overs significantly,” says Katayama. In the latter half of the development period, they came to understand each other without any need for words.
It can be said that the development team’s after-sales follow-up for customers and their attitude of tackling problems in a cross-departmental manner truly embody the philosophy and culture of the Robotics Business Unit, which is manufacturing, sales and technology integration.
Engineering Section, Robotics Business Unit, Solution Business Operations
Eight months after the start of the development project when the team was in the final phase of the prototype evaluation, unfortunately a state of emergency was declared due to the COVID-19 pandemic. “We could neither have a meeting nor collect parts because of the lockdown. We usually outsource our noise test, but we couldn’t attend the test to operate the LCMR200. Therefore, we had to explain to and consult with the external staff at the test site who had never seen our product before to address the problems occurred.
It took a lot of time and effort to deal with what was unnecessary in a normal situation,” says Mukai. Even under these circumstances, however, they managed to release the new model without once changing the development schedule. The development members unanimously say, “Luck was on our side,” “We were extremely happy when the test machine worked at the first trial.” Their comments symbolize that it was really a desperate battle of development.
The LCMR200, which was released in 2020, has been mainly sold in the domestic market under this unprecedented situation, but they are considering expanding into overseas markets. There is no doubt that this new model will make a remarkable advance as a game changer in the automated equipment market.