Case Study

Case Study: Storage Tank Manufacturer Expands Business Using
Kawasaki Robots, Safety System & Tool Changer
Application: Spraying & Material Removal
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With their double-walled underground storage tanks, German
company Haase Group has been a market leader in the tankindustry for more than 50 years and relies on a unique
combination of traditional manual work and modern
automation technology.

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automating more processes

Since their start in 1999, Haase has recorded strong growthsays Managing Director Thomas Falkenbach: "We looked forand found a market niche. This has enabled us to position
ourselves successfully as a pioneer in the field of tanks regarding material, quality and flexibility." But in 2010, theydecided to enhance their tank finishing process using
Kawasaki robots and safety software.
Since the integration of the first Kawasaki robot in 2010, thetraditional manufacturer has not only been able tosignificantly optimize its production and efficiency, but also
to support its sustained growth in many industries andinternational markets.

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different tools+DDVHLQVWDOOHGWKH.DZDVDNL=76URERWWRVSUD\JODVV
fiber reinforced plastic (GRP) onto the double-walled cellar
and underground storage tanks during the finishing process.
The robot is shelf-mounted next to a turntable where theparts are fixed, making it easy to apply an even coat of GRP.
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this application. However, its wide wide working range andhigh precision capabilities make it perfect for the spraying
process specifically. The robot is able to process both single
or multiple lids and bases in series, offering maximum
flexibility and greatly increased efficiency.
'XHWRWKHVXFFHVVRIWKH=76+DDVHDGGHGD.DZDVDNLBX100L robot to the production site, which is also used toapply resin and glass fibers to a mold. They also added
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automatic tool change system. This system provides them theflexibility they need to manufacture approximately 100
different tank types as needed.
Kawasaki FirstThe Kawasaki ZT130L robot has been combined with an automatic tool changesystem and specially developed rotary tables.

CHALLENGES
Aging Machinery

Jürgen Krell, technical director at Haase, decided to go with
Kawasaki Robotics after interacting with them at theAutomatica trade show. "For us, the attractive price, therobust design and the specific but precisely fitting[specifications] of the robot were the deciding factors. With aproven Kawasaki partner in the neighboring town, theavailable service was also excellent for us. And the technicalsupport provided by Kawasaki itself has quickly proven to beparticularly reliable and flexible"

Haase was an early adopter of robotics, installing their firstrobot ini 1991. This upgrade brought a noticeable relief forthe company, so they continued down the path ofautomation. As time went on and the robots grew older,
maintenance and servicing became increasingly difficult.
When it was no longer possible to guarantee reliable
procurement of spare parts in the long term, they knew it
was time to upgrade.
Dusty Environment
A central challenge in the construction and operation of theplant was the considerable amount of dirt and dust produced
during processing. They needed a robot arm suitable for a
dusty environment and a controller that didn’t require
constant cleaning.

The Kawasaki
ZT130L working
the edge of a tankbottom.

Case Study

The palletizing robot places crated bottles on a pallet.

A Cleaner & Safer Environment
A suction system was made to ensure continuous andeffective extraction of dirt during the finishing process,ZKLFKUHPRYHGRIDLUERUQHGLUW7KH=VHULHVURERWV
run on Kawasaki’s E series controller, which only needs tobe cleaned once a week for optimal performance.
Automatic Tool Change
Haase also developed and built a special tool change
station so the robot can efficiently switch between four
different tools needed for finishing. The shelf-mounted=7/URERWLVQRWGHSHQGHQWRQVSHFLDOWRROVáLWXVHV
commercially available machines such as a milling tool toprepare the manhole in the tank and an angle grinder toprepare the tank surface for lamination and furtherprocessing. The robot also uses two saws enable precise
cutting of the workpiece and grinding of the outside of thetank and a suction attachment for a thorough cleaning ofthe lids and bases.

"The successful automation and use
se of robots create thebasis for our further growth. This enables us to meetthe growing demand in a targeted manner.”p Maanaging Direector- Thomas Falkenbach, Haase GroupManaging
Director

Maximum Safety Enhances
Human-RobotEnhan-Robot Collaboration
A light barrier effectively protects the working area of therobot in combination with the Kawasaki Cubic-S safetysystem. Cubic-S ensures that robots and workers can work
together safely and without hesitation. The software
enables the installation of particularly space-saving
applications and security areas without complex external
security measures. Cubic-S combines eight safety functions
áLQFOXGLQJWKHLQGLYLGXDOGHȖQLWLRQDQGSUHFLVHOLPLWDWLRQof the available working space. The robot cannot exceed
the specified working range limits at any time.
For this safety system to work, the individual axes of therobot are electronically monitored. Predefined axis values
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speed is exceeded, previously stopped axes are moved ortools leave their intended orientation, Cubic-S
automatically switches off the robot.

RESULTS
Top: No special tools necessary: The Kawasaki ZT130L at Haase Tank uses
standard milling and sawing machines. From angle grinders to saws - the robot
picks up the correct tool independently.
Bottom: The budget-friendly price, robust design, and specifications of theKawasaki robot made the decision easy for the Haase team.

"We more than doubled our output compared to 2011. The
three Kawasaki robots play an important role in this," says
Jürgen Krell. While the oil tanks are only sold to German
customers, other products such as heat accumulators aswell as oil and grease separators are also in demand on theinternational market - and are exported to Scandinavia,,WDO\'XEDL6RXWKHDVW$VLDDQGWKH86$DPRQJRWKHUV7KH
Swiss Federal Railways, for example, are currently
completely converting their light liquid separators to Haasetanks. "The successful automation and use of robots create
the basis for our further growth. This enables us to meetthe growing demand in a targeted manner," adds
Falkenbach.
He draws a positive conclusion from recent years. "The useof Kawasaki robots has quickly paid off for us and offers us
full flexibility in the long term. Our team is always workingon further optimizing the close cooperation between
robots, tools, extraction system and turntables.”Kawasaki Robotics (USA), Inc.
Corporate Headquarters for Americas
28140 Lakeview Drive, Wixom, MI 48393, U.S.A.
Phone: +1-248-446-4100 Fax: +1-248-446-4200

KawasakiRobotics.com