Robotic automation is becoming more accessible to small manufacturers as the footprint of these robots is shrinking and their use is expanding.
The automation market is growing rapidly: affordable, compact robots and turnkey robotic work cells are available for stores with tighter space constraints and a wider range of needs. New automation technologies, from robotic frames to shelving systems, fixtures, software and more, are streamlining workflow and delivering a high degree of consistency, efficiency and quality.
Modern flexible robots with high reproducibility help to orient, produce and ship parts for low volume, high stock and high stock, low volume stores. The introduction of these robots has improved care, warehousing and non-essential operations, reducing costs and increasing profit per square foot.
The use of robots to control equipment often improves productivity and operational safety while improving overall equipment efficiency. Today’s robots also require less space, compact and lightweight six-axis robots can be installed next to workpieces and machines in existing production lines and cells. These types of robots are great for removing machined parts from chucks and loading milling machines. Robots with powerful drive systems and higher levels of vibration extend this capability to large parts.
Robotic machine control and part picking remain useful entry-level applications for automation. While they benefit most small and high volume workshops, workshops with a wide variety of parts can also benefit from these robots with the right strategy. Photo courtesy of Yaskawa America, Inc.
Most modern robots that control machines have a repeatability of less than 0.1 mm, which allows them to outperform humans in very routine, repetitive tasks. These benefits also extend beyond the machining sector, with press brakes and horizontal injection molding machines (IMMs) also showing increased productivity.
The current wave of multifunctional robots available is also affecting secondary operations such as trimming, laser cutting, laser marking and deburring. In the latter case—whether direct deburring or a hybrid deburring and polishing process is required—small and large parts with different workpiece properties can be assembled. Running secondary tasks in the same space as primary operations saves time and money even more.
Peripherals and other forms of automation can increase the versatility and usability of robots. These can be included when purchasing a robot, but in most cases manufacturers should be able to upgrade peripherals in existing work cells.
The Vision Guided System (VGR) simplifies robot programming, setup and integration. Intelligent machine vision technology helps the robot move and manipulate incoming workpieces, including those located in different places.
Automation goes far beyond machine control – modern robots can perform non-essential tasks such as laser marking and on-site deburring. This adds value to the work done in the robotic cell without requiring a significant increase in space.
Applications that require a mobile robotics solution can use a variety of options. While a single traditional servo robot can still handle large parts or applications that require continuous maintenance of multiple machines, autonomous mobile robots (AMRs) equipped with LiDAR sensors and other machine vision technologies can handle many other tasks. AMRs can independently move around the shop floor to perform assigned tasks, making it easy to reallocate industrial and collaborative robots to perform machine maintenance tasks where specialized robots are impractical. In some applications, stationary robots designed to work collaboratively can load and unload items from the AMR.
Robot integration can be easily managed through standard programming environments without the need for proprietary programming languages. Operators can easily set up a robot with a motion control platform or programmable logic controller (PLC) to use these devices for a variety of applications. For example, a software interface could allow a robot to “know” where a particular product is located and perform actions on that product as needed. Popular Rockwell actuators can be connected back to the PLC for position, speed and feedback information, providing the robot program with the information it needs to track product along the conveyor belt and keep the robot running in a safe area.
The EuroMap 67 compliant electrical interface is a hardware/software system that further simplifies these tracking processes. The best interfaces conform to the Plastics Industries Association (PLASTICS) standards for conveying valuable information such as door status, robot operation, and catapult position.
With a wide variety of bots to choose from, there are some ongoing developments to be aware of. When considering which robot model to buy, it is helpful to weigh the capabilities and needs of a particular robot. Guardrail requirements and the possibility of using artificial intelligence are important aspects to consider in relation to robots and robotic operations.
Depending on the application, guards are not always required – collaborative robots often do not need them, and even some traditional industrial robots can work without interference. In some cases, only safety devices such as area scanners or light curtains are required. However, for manufacturers who consider the total area of their workspaces, the use of safety fences can be ideal, even for shared applications. Cycle time requirements should be considered depending on the option selected, as the speed of the robot is a safety factor for the operator.
Vision-equipped AMRs can not only be used as mobile tool carts and workpiece holders, these vehicles can also easily move industrial and collaborative robots around the shop floor to meet changing needs.
In terms of artificial intelligence (AI), advances in the field are enabling robots to navigate safely and cooperatively in 3D environments, even when working with complex types and shapes of parts. AI also plays a role in AMR as these vehicles autonomously maneuver around objects to complete certain tasks in a timely and safe manner, using installed robots, vision systems, special tools at the end of the arm, and more to get the job done.
When implemented intelligently and effectively, robotic systems hold the potential for future success. While changing customer demands, supply chain challenges and skilled labor shortages will continue to change the industrial landscape, robots can solve many of these problems, improve productivity and keep operations running smoothly.
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Post time: Mar-06-2023