Industrial robot technology is on the move, with advances in design now producing robots with human-like flexibility. Katherine Crichton reports.
FOR many Australian manufacturers, robots have become a fact of life for those endeavouring to remain profitable while confronted with low-cost global competition.
There are about one million industrial robots globally, with almost half that number in Japan and numbers steadily increasing in the US, and in spite of its low-cost labour image, China is also rapidly adopting robotics systems to increase competitiveness.
According to Peter Davis, national marketing officer with Robotic Automation (RA Group), one of key trends in industrial robotics is increased flexibility in a much smaller footprint.
“We are now seeing robots with human-like movement while taking up only a human-sized space in existing plant layouts.
“This opens up a much broader opportunity for manufacturing applications, especially in existing plants where space is very short and valuable,” Davis explained.
Robots incorporating a 7-axis design with ‘snake like movement’ are now emerging, enabling human-like flexibility coupled with the ability to manoeuvre in very tight areas previously inaccessible by conventional robots.
Davis cites the example of the IA20 robot which can straighten out vertically to take up only about 1 square foot of floor space or straighten out horizontally at a height of about 2” above the floor and can be mounted on or between machines (floor, ceiling, wall-, incline- or machine-mounted).
“This kind of flexibility is made possible by the actuator-driven motors and transmissions, which are responsible for the movement of the robot, which have been built into each robot axis with the supply cable running through the arm.
“This enables the robot to move freely without cable bundles being in the way, and to be able to sneak into very tight spots,” Davis told Manufacturers’ Monthly.
“Through-arm power and air cabling is also available to the end-of-arm gripper/tool – reducing cable wear, twisting, and avoiding the limitations in movement caused by cable interference.”
“The robots offer all the traditional benefits of conventional robots —increased productivity and accuracy, reduced labour and lost production time – while being able to do more intricate tasks in tighter spaces,” Davis said.
Robot on Robot
Some of the key areas where robots perform better than humans are in applications that require accuracy and repeatability, so the ability to have several robots working together has many benefits for manufacturers.
While engineers five years ago may have had trouble co-ordinating the efforts of two or three robots, with today’s sophisticated algorithms, they can manage dozens.
According to Jeff Fordham, sales manager Machinery Automation & Robotics (MAR), there is an increase in multi-robot applications, which can see up to four robots (or 36 axes of movement) working simultaneously.
“In the instance where multiple robots work co-operatively, a single robot controller has enough processing power to control multiple robots,” he told Manufacturers’ Monthly.
“Each additional robot may only require a servo pack which has several advantages.
“These include a reduction in the amount of integration of signal and safety circuits, less hardware with lower investment costs, and easier for operators to control the system through a single teach pendant,” Fordham explained.
“Advances in the protection levels of robot manipulators are also allowing robotic and automation companies to progress with robotic applications in wet areas such as food and meat processing facilities.”
Fordham also points to improvements in higher payload robots and advances in the teach pendant displays for use as the Human Machine Interface (HMI) resulting in exciting new levels of functionality for jobs that were never before considered practical for robots.
“Increases in the safety levels and sensing systems of robot control systems are now allowing personnel to interact with robots to move heavy components, particularly in the automotive industry.”
While robots are rapidly evolving into a broad range of structures and mechanisms, some not immediately recognisable for what they are, Davis and Fordham explain while the technology is allowing robots to perform more complex tasks, it can be harder for potential users to fully comprehend the more intricate abilities of these systems.
“It is recommended for any prospective buyer to meet with existing users and suppliers of robot systems to understand the technical capacities for robotic systems,” Fordham told Manufacturers’ Monthly.
“Many robot brands may be able to complete a task, but the additional system components such as in-feed conveyors and gripper systems are often required to be engineered and built for their specific application, in which case an experienced systems integrator should be sourced,” he said.
Davis agrees and says that the biggest challenge for manufacturers is in realising the most efficient and appropriate place for robotics in their production.
“Be sure to select an integrator with as much experience as possible. While there are differences in performance between robots from different brands, in many cases the difference is very negligible to the result when compared to the skill of the company integrating the robot into the solution.
“The design of the complete robot cell from work-piece positioning or product accumulation and orientation, through to end-of-arm tooling design (such as grippers), PLC control, operator interface, and programming of the robot movement… all have a big impact on the final performance,” Davis said.
Fordham suggests manufacturers ensure that any new technologies are proven in the early stages of the project.
For more information contact:
MAR: mar@machineryautomation.com.au
RA Group: webenquiry@ragroup.com.au
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