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Factory Automation

Industrial Robots - MELFA | MELFA Smart Plus

Automating the World

Advanced robotic technologies are redefining the way manufacturers improve productivity, accuracy, and operational efficiency. From AI-assisted force control and automated calibration to intelligent maintenance and motion optimisation, these innovations help reduce setup time, enhance process reliability, and maximise robot performance throughout the entire production lifecycle.

Enhanced Force sensor Sense Control

Faster Setup and Higher Process Reliability with AI-Assisted Force Control. 

The AI-powered Force Sense Control Enhancement automatically tunes force control parameters through a short and guided learning process. It supports demanding assembly applications such as insertion, fitting, phase-matching insertion, and contact detection, significantly simplifying the setup of force-controlled processes. It reduce commissioning effort because the system automatically identifies suitable parameters that would otherwise require extensive manual optimisation. This shortens setup times, improves process stability and allows engineers to bring applications into production more quickly.

Automated calibration and alignment control

Automatic calibration simplifies and automates the calibration process between robot and vision systems. 

The solution automatically teaches multiple reference points and angles, ensuring highly accurate hand-eye and camera-robot calibration with minimal manual intervention. Additionally, it can calibrate the relationship between the robot and workpieces, fixtures, or peripheral equipment using vision technology. Common coordinate systems can be shared across multiple robots, ensuring consistent positioning throughout the production environment. The calibration tasks that require significant expertise can be completed more quickly and consistently, reducing setup time and improving productivity

Coordinated control of additional axes

The function can expand robot reach and allows synchronised operation when a robot is installed on an additional axis (linear axis) to handle large workpieces which exceed robot’s working range. It also synchronise operation when tracking of the robot with a workpieces on an additional axis (linear axis) is executed. The advantage is to process larger products without investing in additional robots.

Robot Mechanism Thermal Compensation function

Robot Mechanism Thermal Compensation automatically corrects positional deviations caused by thermal expansion within the robot structure. The system maintains high accuracy throughout warm-up periods and demanding production cycles without requiring external temperature sensors. The main benefit is the consistent precision over long operating periods, resulting in improved product quality and fewer rejects caused by thermal drift.

Preventative Maintenance

It monitors the consumption degree of critical robot components using a dynamic model and real drive data. By analysing actual operating loads such as force and speed, the system estimates the wear of key components including reduction gears, ball screws, belts, bearings, and grease. Maintenance schedules are optimised according to the robot's actual operating conditions rather than fixed service intervals. This finally results in reducing unplanned downtimes.

Maintenance simulation

Optimise maintenance planning before operation begins. Using offline simulations in RT ToolBox3, the system estimates component replacement intervals and recommended maintenance schedules based on the robot's specific motion patterns and operating programs. Robot lifetime can be evaluated during the design phase, allowing engineers to compare different operating scenarios and identify machine-friendly movements that reduce wear. By balancing productivity requirements with component lifetime, robot programs can be optimised to extend service life and lower maintenance costs.

Predictive maintenance function as optional features

Detect reduction gear abnormalities and component deterioration at an early stage to help prevent unexpected downtime. The system continuously monitors the condition of the robot's reduction gears and analyses related encoder data and communication status. When abnormal conditions are identified, the system can generate warnings, enabling timely maintenance actions before failures occur. Current condition and diagnostic information are displayed through predictive maintenance messages, providing clear visibility into the robot's health status.


• Available with the MELFA Smart Plus Card (2F-D521) or the iQ Care MELFA Support SD Card installed in the robot controller.

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