Assembly Technologies

TM TM

NEW SOLUTIONS IN MATERIAL HANDLING

Complete material handling solutions

A New Solution
Stanley Assembly Technologies, a Product Group of The Stanley Works, provides solutions to the industrial assembly market, including the motor vehicle industry. Core solutions include high-performance DC electric and pneumatic tightening tools and controllers, conventional pneumatic articulating arms, torque tubes and now Intelligent Assist Devices for ergonomic material handling. With our Cobotics product line, Stanley is a leader in the growing market for Intelligent Assist Devices (IADs). Engineered to dramatically improve the productivity, quality and ergonomic safety of assembly operations, IADs are computer controlled, servo powered lift assist devices that assist workers in lifting and manipulating heavy and awkward parts.

Proven Technology & Experience

With more than 40 years of experience in providing engineered solutions Stanley has the expertise to tackle your most challenging material handling needs. By combining standard products such as manipulator arms and end effectors with cutting edge Intelligent Assist Device (IAD) technology Stanley offers a complete range of ergonomic lift assist solutions ideal for any industrial environment. Our engineers are experts in evaluating customer needs and converting them into solutions that improve the productivity, ergonomics, and quality of your manufacturing operations.

Technical Support
As a supplier to the assembly market, Stanley has developed a global sales and service network to support the manufacturing operations of our customers. Stanley offers many levels of customer support from basic maintenance & operator training to full service repair facilities and maintenance service contracts.

Designed to boost the bottom line.

Stanley material handling solutions are designed to improve your operations by: Increasing Productivity Improving Quality Enhancing Ergonomics Error Proofing Tasks

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From basic components to intelligent systems

Arms Rail Systems

Torque Tubes & Vertical Balancers

End Effectors

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Assembly Technologies

Intelligent Assist Devices

Introducing Cobotics, the next generation in Material Handling
Intelligent Assist Devices (IADs) enable true collaboration of a human operator with computer-controlled machinery to provide load movement with greater speed and

Material handling solutions that work harder and smarter.

Improve Ergonomics Increase Productivity

control than ever before possible. IADs greatly enhance traditional material handling methods with intelligent motion control that optimizes lifting, guiding, and positioning movements. With a humanmachine interface that feels natural and transparent, IADs increase productivity while reducing harmful forces on the operator's body. Virtual guiding surfaces can further improve the speed and smooth movement of loads, for reduced part damage and higher quality. Many companies have increased productivity by as much as 70% using IADs. These companies are replacing their traditional assist devices with IADs, resulting in increased line speeds while reducing cumulative trauma injuries and improving quality.

Axle Sequencing Transfer from rack to sequencing cart

Instrument Panel Handling Transfer to shipping rack

Improve Quality

Reduce labor costs

Cockpit Install Prevents collision with vehicle

Catalytic Converter Test Cell Transfer between multiple operations

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Flexible Configuration Options

Cobotics IAD components can be used in combination with traditional Stanley material handling solutions to enable complete adaptability to the demands of your application.

The Cobotics Control Advantage.

At the heart of every Stanley Cobotics IAD is leading edge control technology that enables the operator and IAD to work in tandem-for swift, smooth, and precise movements. This advanced control system with closed loop feedback allows the IAD to adjust to changes in load mass and operator intent. By masking the friction and inertia of the overhead support structure and eliminating overshoot, the operator can focus on the payload - rather than the assist device. Cobotics is the IAD Pioneer As the founders of IAD technology in 1995, Stanley offers unmatched experience and applications expertise in the field. We provide: Multi-Axis IAD Components The Stanley Cobotics family of IAD products can be combined to create multiaxis solutions. Configurable for specific applications, these reliable systems utilize proven servo technology for superior, lasting performance. IAD System Solutions Stanley offers both IAD component sales as well as turn key IAD material handling solutions, including rail system and end effector design/installation. With over 40 years experience of implementing assembly solutions, Stanley is positioned to support the global assembly market. Cobotics IADs use "intent sensors" (patent and patent pending) to quantify the speed and direction of the motion that the operator requires. Proprietary algorithms then direct the movement of the IAD. Integration support and training With our sales, service, and distribution network, we provide installation support and troubleshooting. We also offer training programs for systems integrators.

The industry's highest performance lifting and balancing system, offering highly intuitive lift assistance with a patented float mode. The iLift interfaces with interlocks and actuators on end effectors, and allows individualized responsiveness profiles.

Unequaled speed and ease in load positioning for rigid and cable based systems on both monorails and bridge cranes. Providing easy mounting with all conventional rail profiles (both new and existing installations), quick programmability from its central hub, semi-automation, and much more, the iTrolley helps get the highest performance and productivity from overhead rail systems.

Assembly Technologies
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Intelligent Lifting & Balancing

Installation on existing or new rails from all major rail manufacturers.

User Profile Selection

Does your lift equipment slow you down?

Operators select system sensitivity.

Load Cell
with Swivel Attachment

System Status

Having trouble meeting productivity goals?

Virtual Limits
Constrain lift movement between vertical boundaries, preventing overtravel.

Serial Programming Port

Float

Stop

Start

System Stop Float Mode Enable Button

System Start Button Auxiliary Button

with Programmable Functionality

Are upper extremity strains and injuries increasing in your plant?

Hub
Programmable central hub is like a mini PLC, providing programmable I/O for end effector functions as well as a PC or PDA connection for system configuration.

Would you like to enhance the functionality of your end effector?

Slide Handle

Optional Pendant Handle

Low-effort proportional control buttons for precise up/down movement of awkward or hard-to-manipulate loads.

Allows easy, power-assisted up-down movements. Operators simply grasp and gently pull up or down. Can be remote mounted for maximum flexibility.

Optional remote slide handle available for end effector integration.

Intuitive Control Provides Fast, Precise Movement

Stanleys iLift, the most advanced lifting and balancing system available, allows operators to manipulate loads with greater speed and precision than ever before. By simply grasping the slide handle or the load itself and gently applying force in the desired direction, the operator can manipulate payloads as if they weighed ounces. Operators can meet productivity goals while reducing ergonomic strain, with programmable virtual limits, user-selectable operating profiles, and vertical speeds up to 295 ft/min (1.5 m/sec). Offering a blend of power assist and hands-on (float mode) load positioning, the iLift combines computerized control with human manipulation. The iLift maximizes the capability of end effectorswith a programmable hub featuring internal logic for control of end effector functions via air cylinders, interlocks, proximity switches, and a locally mounted E-Stop. Allowing easy installation on existing or new rail configurations, quick programmability, and semi-automation, the iLift is the highest performing lift assist available today.

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Flexible Configurations
Trolley or rail applications The iLift mounts to most standard trolleys and rail profiles and allows seamless end effector interface. It can also be configured with the Stanley iTrolley to create multi-axis Intelligent Assist Device (IAD) systems. Interface with rigid arm configurations For added versatility, the iLift can also be configured to provide vertical lift for rigid arm systems.

Features
Slide or Pendant Handle Choose from two handle configurations for direct, hands-on or proportional pushbutton control. Float Mode Featuring an advanced patented float mode, the iLift enables: Hands-on (float mode) fine tuning of load position. Automatic mass estimationno need to push a button each cycle. Movement of loads without the need to push buttons from the central control positionshaving seconds from cycle times. Virtual limits Easily programmable virtual limits prevent load damage and enhance productivity by constraining up/down movement.

iLift Specifications
Capacity:

150 lb.

500 lb.

150 lbs. 500 lbs. 68 kg. 226 kg. 137 fpm Maximum Lift Speed: 295 fpm 1.5 m/s 0.7 m/s 1G 0.5 G Acceleration: 9.8 m/s/s 4.9 m/s/s 120 in. / 3048 mm Vertical Travel: Continuous (>H5) Duty Cycle: 120 V AC 220 V AC Power Requirement: 1 Phase 1 Phase 15 amps Max. Current Draw: 1/8 in. 3/16 in. Wire Rope Diameter: 3.18 mm 4.76 mm 71 lb. 133 lb. Unit Weight: 32.2 kg 60 kg 12 V 3 amps Hub Power Available: 3 digital, 3 analog Hub Inputs: Hub Outputs: 2 digital, 1 Interlock, & 1 E-Stop

500 lb .

Cap.

Access to system information Valuable feature for analyzing real-time conditions of the IAD system. Examples include: Maintenancetracking preventative maintenance schedules Error-proofingcomparing actual load weight against an expected value Optional Ethernet connection enables communication with user plant information systems Locked position Permits drift-free payload changes, ideal for dumping applications. Self-contained unit The iLift is completely self-contained, with on-board controls requiring only 120 V AC power.

NEW
500 lb. Capacity Unit Now Available

Benefits
Greater productivity Faster cycle times are achieved with the systems speed, float mode, and semiautomation features, allowing operators to accomplish more in a shorter period of time. The iLift offers continuous, variablespeed lift control with a maximum speed up to 5 times faster than speeds offered by standard hoists. Eliminates vertical overtravel The responsive slide handle allows stopping precisely in the intended position, with no noticeable delay. Error-proofing automatically compares actual load weight to an expected value. By identifying loads that are either under or over the expected weight, operators can easily and reliably identify errors that may have occurred in assembly or packing operations.

Additional system features Precision set-down Speed reduction points Load interlock Odometer function Anti-recoil Capacity overload protection E-Stop

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Intelligent Rail System

End Truck Installation on existing or new rails from all major manufacturers. Specify 2 iTrolley (3 runway) or 3 iTrolley (2 runway) configurations.

Does your ergonomic assist equipment slow operators down?

Bridge Crane

End Truck

Are upper extremity strains and injuries increasing in your plant?

Vertical Lift Device

Easily interfaces with iLift or air balancers.

Cable Angle Sensor

Senses operator intent with reliable, non-contact sensor (patented).

Virtual Surfaces and Limits

Constrain trolley movement along the bridge/runway, guide operator motion, prevent overtravel or collision.

Do you need more control of your process to improve quality?

Hub
Allows programming of system parameters such as speed, acceleration, sensitivity, and virtual limits.

Do you need to add error proofing?

Unmatched Productivity. Unparalleled Ergonomics.

With Stanley's new iTrolley for enclosed and patented track rail systems, moving loads with large unwieldy bridge cranes is now possible with greater speed and precision than ever before. The system masks the momentum and inertia of the overhead crane, greatly reducing the starting-and-stopping strain that causes most operators to abandon the equipment and perform the task manually. The servo-driven iTrolley is the highest performance drive system ever created for enclosed and patented track rail systems. The system utilizes a collection of intent sensors, such as the cable angle sensor, that measure human intent and command the iTrolley system to respond as if it was an extension of the human operator. Providing easy mounting with all conventional rail profiles (both new and existing installations), quick programmability from its central hub, semi-automation, and much more, the iTrolley helps get the highest performance and productivity from overhead rail systems.

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Flexible Configurations
Monorail or bridge crane applications Depending on the application, a one, two, or three-trolley system can be installed. Using the iTrolley for horizontal movement, vertical lifting can be accomplished with a Cobotics iLift or standard air balancer. Versatility iTrolley interfaces with both cable-based and rigid arm lift assist systems.

iTrolley Specifications Maximum Velocity: 2.0 m/sec (393 ft/min) at 300 lbs. per trolley Maximum Acceleration: 0.4 G peak acceleration at 300 lbs. per trolley Primary Power: 120VAC Current Draw: 20 amps max (for 3 trolley system) Maximum Trolley Load Capacity: 1000 lbs. (454 kg) Maximum Travel: Unlimited runway travel

Benefits
Greater Productivity Fast, accurate movements with improved ergonomics and semi-automation help operators work faster, for longer periods of time. Tests show an average of 57% greater productivity compared with manual systems.

Features
Non-contact Cable Angle Sensor This exclusive patented sensor detects the operator's movement in the intended direction and provides immediate power assist. Eliminating the need to push multiple buttons, the operator simply grasps the load and pushes it in the direction they want to travel. The non-contact cable angle sensor measures the proportional deflection of the cable and the intelligent system responds as quickly as the operator moves. Virtual Limits Programmable from the Hub, virtual limits prevent load damage and enhance productivity. Disengage Function The iTrolley drive is easily disengaged for service or for manual backup.

Maximum Bridge Length: Up to 9m (30ft) bridge length Compatible with the following: Stanley, KBK, Knight, Unified, Zimmerman/IR, CES, Patented Track & I-Beam Programmable Hub with RS232 interface As the high-speed communication link and main operator interface, the Hub allows the user to: Easily set up, configure, and program the system with a laptop. Program and switch between operator preferences for speed, acceleration, and sensitivity. Perform data collection for QA/QC, error correction, and tracking.

Productivity
57% increase 7
Results may vary depending on application

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cycles per minute

Manual trolley

iTrolley

iTrolley increases productivity by reducing push/pull forces and amplifying strength.

Reduced Strain By masking the inertia and momentum of the overhead load, the iTrolley greatly reduces the push/pull forces as well as the energy required to perform each cycle. Eliminates Overtravel iTrolley stops precisely on the intended mark, eliminating the productivity losses associated with multiple repositioning. Semi-automation With commands such as return to home, the iTrolley can automate portions of the load movement process, freeing operators to perform secondary tasks.

Effectively Minimizes the Force Required to Start/Stop a Load. Manual Bridge Crane

60 40 20

60 40 20

force (lbs)

0 -20 -40 -60 -80 0

load
315 lbs 225 lbs 180 lbs 135 lbs 90 lbs

force (lbs)

0 -20 -40 -60 -80 0 Average 77% lower force to stop load. 2 4 time (sec) 6

4 time (sec)

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RailCobot Intelligent Arm System

Installation on existing or new rails from all major manufacturers. End Truck

Power Rotate
Provides additional axis of power-assist and control.

Do you need highly responsive power assist in your arm application?

Bridge Crane

End Truck

Vertical Movement

Are you having trouble meeting your productivity goals?

Can be achieved with pneumatic or electrical cylinder.

Hub Virtual Surfaces and Limits

Constrain trolley movement along the bridge/runway, guide operator motion, prevent overtravel or collision. Allows programming of system parameters such as speed, acceleration, sensitivity, and virtual limits.

Does your ergonomic assist equipment slow operators down?

iGrip

Multi-axis intent sensor

Are upper extremity strains and injuries increasing in your plant?

A Better, More Powerful Ergonomic Arm Solution

Gain high productivity while minimizing operator injury, with the ultimate power assisted solution, the RailCobot Intelligent Arm system from Stanley. The RailCobot system offers the most intuitive power assist technology available with automation features such as virtual limits and line tracking. The system delivers greater productivity as compared to manual methods. When the operator begins to push on the iGrip, the RailCobot actuators provide instant power assist in the desired direction at 90% less ergonomic force. The RailCobot system fits applications such as automobile seat and door assembly, instrument panel install, engine/transmission and drive train assembly, handling of large sheet metal, and movement of parts in and out of racks. Using Cobotics' iTrolley components, the RailCobot System easily integrates with most conventional rail profiles and helps realize the highest performance from manipulator arms.

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Flexible Configurations
iTrolley interfaces with existing or new manipulator arms The iTrolley System can add power assist to existing or new manipulator arms. This addition maximizes productivity, quality and ergonomics for arm applications. Monorail or bridge crane applications Using the iTrolley for horizontal movement, vertical lifting can be accomplished with a pneumatic or electric cylinder, Cobotics iLift or air balancer. The System also integrates seamlessly with end effectors.

Quality: Virtual Surfaces Reduce Collisions

Moving Conveyor

Virtual Surface

IAD with operator Intelligent rail system

Increases productivity Fast, accurate movements with improved ergonomics and semi-automation help operators meet the ever increasing need to reduce cycle time. Semi-automation Using commands such as line tracking and "return to home," the iTrolley can automate portions of the load movement process, freeing operators to perform secondary tasks. Automated functionality includes:

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Line tracking capability in which the system is synchronized with a line or conveyor, allowing operator and line to move together easily.
Network capable for communication with plant information systems. Error proofing Virtual surface capability enables the RailCobot to pick only from a selected rack, thus preventing the use of incorrect parts.

Features
Intent sensors follow the direct movement of the operator to provide power assist with no physical strain. The sensors quantify the speed and direction of motion that the operator requires. Proprietary algorithms then direct the system's movement. Virtual surfaces and limits enable the programming of virtual surfaces, paths or funnels to ensure swift, efficient movements without collision or load damage. I/O & communications capability The Cobotics system can interface with plant control systems or PLCs to provide additional functionality such as error proofing a task or transmitting system status to the maintenance group.

Benefits
Intuitive power assist The RailCobot System provides instantaneous power assist in response to operator movements. It uses "intent sensors" to track operator motions without noticeable delay. This dramatically reduces the forces that the operator must apply. Reduced strain and improved ergonomics By masking the inertia and momentum of the arm and load, the iTrolley System greatly reduces the push/pull forces as well as the energy required to perform each cycle. Eliminates overtravel iTrolley stops precisely on the intended mark, eliminating the productivity losses associated with repositioning.

Ergonomics
RailCobot systems reduce push/pull force

lbs.

93% decrease

Cobotics 5 lbs.

Manual 77 lbs.

Results may vary depending on application

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Assembly Technologies

GLOBAL LOCATIONS
WORLD HEADQUARTERS STANLEY ASSEMBLY TECHNOLOGIES 5335 Avion Park Drive Cleveland, Ohio 44143-2328 USA Tel: +1 (440) 461-5500 Fax: +1 (440) 461-5592 SATINFO@stanleyworks.com STANLEY ASSEMBLY TECHNOLOGIES Applications and Productivity Center 5800 Enterprise Court Warren, Michigan 48092 USA Tel: +1 (586) 393-1100 Fax: +1 (586) 393-1200 Toll Free Service: (877) 787-7830 Toll Free Sales: (877) 709-8006 STANLEY WORKS Ltd. (FRANCE) Outils Portatifs et Systemes d'Assemblage Zone Imoparc bat Loire 4, 78190 Trappes, France Tel: +33 (1) 3050 9100 Fax: +33 (1) 3051 0708 STANLEY GERMANY, Inc. Frankfurter Strasse 74 D-64521 Gross-Gerau, Germany Tel: +49 (0) 6152 8052-0 Fax: +49 (0) 6152 8052-22 SATGER@stanleyworks.com STANLEY TOOLS S.r.l. (ITALY) Divisione Assembly Technologies 47 Via Parco, 20046 Biassono (MI) Tel: +39 (039) 2389.1 Fax: +39 (039) 2389970 STANLEY ASSEMBLY TECHNOLOGIES Gowerton Road Brackmills, Northhampton NN4 7BW England Tel: +44 (1604) 827247 Fax: +44 (1604) 827277 THE STANLEY WORKS SHANGHAI REPRESENTATIVE OFFICE Room 1908, Shanghaimart Tower, 2299 Yan An Road West Shanghai 200336, China Tel: 011-86-21-3208-4550 Fax: 011-86-21-6236-0191 www.StanleyAssembly.com

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STANLEY in a notched rectangle design, the Cobot logo, and are trademarks of The Stanley Works or its affiliates in the United States and elsewhere.