dBhatt

Dispensing is one of the many tasks that a robot can do. There are several aspects that need to be understood before selecting a good dispensing robot. Let’s go through them to try to make things clear.

What is it? How does it work?

As the name suggests, a dispensing robot is any robot that dispenses a variety of items such as adhesives or paint. Other than dispensing materials, it also sometimes sorts and counts items, transfer parts or fills up tanks.

Their most important characteristic is that they are leak and ejection-proof. The nozzle end opens up to pour or dispense a specific predefined quantity of material or fluid at a specified location. It then closes. They use methods like precise shutoff and “suck back” to reduce the wastage of fluids via diaphragmatic valves and motors.

Types and applications

There are various types of dispensing robots available on the market adapted to all sorts of requirements. These types are defined by the kind of material they are dispensing, the needed speed and accuracy, which number of axes are required, and also which industry the robot will be used in. In light of that, two broad categories emerge One to three-axis robots and four to six-axis robots. Let’s look at them in-depth:

One to three axis: These robots are only capable of linear motion, and lack rotational movements because they are limited between one to three axis. This being said, thanks to their limited movement, they can operate with high speed and accuracy. One example of this is a benchtop robot. One axis is controlled by the bench and the other by the Cartesian robot mounted on top. Similarly, SCARA are also in this category with (3-4 axis) variants. A classic example of this robot type is the toothpaste filling robots in the consumer goods industry.

Four to six-axis robots: Capable of moving in multiplanes, four to six-axis robots are also called robotic arms. They have joints that enable linear movements but also rotational movements. This allows these dispensing robots to work on angular planes, multiplanes, and dispense fluid in a rotational motion. A classic example of this kind of robot is the paint robots used in the automotive sector. Applications range is:

• Electronics
• Plastic parts in plastic industry
• Automotive
• Aerospace
• Pharmaceutical
• Paint dispensing
• Wax seals
• Adhesives

Benefits

Among the many benefits of automated dispensing, the increase in throughput and assurance quality of the product and process, for manufacturers, is really quite cost-effective in the long run. To list a few more benefits, dispensing robots:

• Increase throughput
• Increase process reliability and repeatability
• Reduce unwanted dispensing
• Reduce manufacturing time
• Guaranty accuracy, irrespective of dispensing surface
• Increase the ROI
• Remove safety issues in manual dispensing
• Reduce manufacturing costs

Choose the best fit

The selection process of the proper dispensing robot is an important aspect when aiming to obtain full benefits. The following factors should be taken into consideration to insure the selection of the proper dispensing robot:

• Dispensing methodology
• Dimensions of the robot
• Size of the part or fluids
• Material loading
• Robot speed
• Number of axes required
• Dispensing path and movement in axis
• Add-on capabilities to work across production lines

One of the most important things to remember when choosing any robot is that they are not supposed to replace the human workforce but rather increase the efficiency, reliability and throughput of that workforce’s production line. Automation in dispensing robots allows this operation to run around the clock. This solution is certainly not perfect, but the benefits are considerable. Once all the conditions to choose the correct robot are met and the right path is selected, a manufacturer will see a visible difference in their output.

Contact us for more information about our robotic cells that could fill up a dispensing task.

References

• Roboworx, “Dispensing Robots,” 19 08 2021.
• Assembly, “Implementing Dispensing Robots,” 06 12 2005.
• M. building, “Considerations when choosing a dispensing robot,” 11 08 2020.

“Packaging can be a theater, it can create a story.”  ̶  STEVE JOBS

According to an Allied Market Research report, the global market for packaging robots is set to reach $4,649 million by 2023. Clearly, packaging is an important aspect of the manufacturing industry. Apart from protecting the product, packaging also improves the marketing of the product itself and its company.

Automated packaging installations not only provide quick ROI when deployed, but they also bring speed, accuracy and productivity to the production line. Let’s get into what packaging robots really are.

As the name suggests, packaging robots are used to palletize, carton and case products. Packaging can also include various other aspects like labelling, sealing or filling.

These robots mimic human hand movements to pack products. This allows them to pick, move, seal, label and pack. Different end of arm toolings can be added to the robot to best fit the product requirement. Articulated and delta robots are commonly used for packaging due to their degree of motion.

Benefits

Automated packaging installations give industries a huge boost in their productivity by reducing the time spent on this task. In the long run, this makes them far more cost-effective than manual labor.

Packaging robots are also quick between tooling changeovers. Their accuracy avoids damages caused by accidental drops or scratches. Using packaging robots can even prevent contamination in industries where it can be an issue like medical or food & beverage.

With the 6 axis robots, their movements, similar to the human arm, bring agility and allow for more complex manipulations. Packaging robots can also have a small footprint because of their capacity to be mounted in numerous ways. This helps save factory floor space.

Packaging robots require minimal maintenance and are capable of working in harsh conditions like fumes, dust and high temperatures. Unlike humans, they can operate 24/7. This increases the company’s production capacity without sacrificing the production efficiency and the quality of the product.

What to look for when choosing a packaging robot

Speed.

The packaging robot must match the speed of the production line. It helps speed up the whole production line and reduces the floor-to-market time of the product.

Flexibility.

The packaging robot should be compatible and flexible with a variety of product picking and placing. They could also be flexible to do other tasks such as labelling, palletizing, sorting, binning and more, if needed. Therefore, quick changeovers are a key point. Robots with a higher degree of freedom allow quick changeovers. There are automated tool changers available on the market which can reduce downtime.

Number of Axes.

Speaking of degrees of freedom, the number of axes is another key point manufacturers need to consider when investing in packaging robots. The more axes the robot has, the more flexible its actions will be. This minimizes downtimes and increases the productivity of the plant.

Budget.

This point tends to be overlooked, but the budget will help determine which compromise needs to be done to achieve the best ROI. To get the most out of a packaging robot, at DIY Robotics, we have a whole product line of affordable robotic cells. Contact one of our experts to find the perfect fit for your project.

Thanks to all the benefits mentioned above, like speed, accuracy, agility, and productivity, packaging robots are a great solution to boost profits. At DIY Robotics, we have succeeded in implementing all of the above-mentioned factors in our robotic cells. They are compact, customizable, mobile, and don’t require any specialist to program them. The cells are pre-fabricated solutions that enable manufacturers to simply plug and play them on their existing floor plan without any major changes in the blueprints. The integration of DIY Robotics modular cells on your floor will give you an edge over others on the market.

References

• D. Roberge, “Why Robotic Packaging Automation is the Future,” 11 05 2018. [Online]. Available: https://www.industrialpackaging.com/blog/why-robotic-packaging-automation-is-the-future.
• G. systems, “An Overview of Packaging Robots Benefits and Capabilities,” [Online]. Available: https://www.genesis-systems.com/blog/an-overview-of-packaging-robots-benefits-and-capabilities. [Accessed 14 09 2021].
• mpac-langen, “Robots in packaging industry,” [Online]. Available: https://mpac-langen.com/resources/example-resource/. [Accessed 14 09 2021].
• Robotworx, “Benefits of Using Packaging Robots,” [Online]. Available: https://www.robots.com/articles/benefits-of-using-packaging-robots. [Accessed 14 09 2021].

The metal industry is one of the biggest revenue-generating industries in today’s economy. It impacts various end-user applications and caters to a vast range of sectors: agriculture, automotive, medical, aerospace, construction, electronics, and many more. As it is such a huge industry, it needs automation to meet the standards and production rate of the demanded supply.

Robots accomplish various jobs in the metal industry. These tasks can vary from part handling to welding, assembly, painting, and cutting.

Let’s delve into some of the automation possibilities that robots can handle in the metal industry:

Part Handling:

This is one of the most common, yet one of the most necessary usages of robots in the metal industry. Part handling is basically picking either raw material or a finished product from one spot and placing it in another designated spot. It can also involve the robot operating with another machine like a forming press, a CNC, etc. Tasks included are, but are not limited to

• Loading
• Unloading
• Palletizing

• Selection of parts
• Reorienting
• Sorting

• Operating with classic metal industry machine (Press, Laser cutting, Plasma cutting, etc)

It allows the handling of large, heavy, and dangerous objects safely on a large scale and at a fast pace. Moreover, it provides high repeatability and efficiency with minimal changeover time between products.

Robotic Deburring:

Deburring is a necessary and important step in the metal industry as this makes the product more client-ready. This means high repeatability is needed for products to be consistent. When done by humans, errors increase and repeatability decreases. Automation helps manufacturers yield higher profits in a medium to long-term perspective. Robotic deburring also improves the quality of the produced part thanks to the fact that the robot’s settings and toolings can be customized according to each of the part’s requirements and be compliant with some part variations. This helps minimize defects.

Have a look at our DIY-Robotics Deburring Cell Bundle, developed in partnership with ATI Automation and RoboDK.

Robotic Painting:

Metal painting has always been a health hazard for humans as it involves toxic components. Thankfully, robotizing this task helps reduce risks for workers. Also, robots have more consistency and precision than humans when applying paint.

In the automotive industry, some robots are used for paint jobs. GM motors and Volkswagen are good examples of this. Robots can do the initial primer, electrostatic, and final coat of paint in a short amount of time. They offer high flexibility, high quality, more control over the process, and all the while, decrease paint and material costs.

Robotic Welding

Welding is an operation where precision and consistency are both very much required. Due to this demand for precision, robotic welding has been a part of the metal industry for a long time.

Robotic welding guarantees high quality and high quantity welding with accuracy and repeatability. There are different types of robotic welding: laser, plasma, arc, TIG, MIG, and others. This technology saves industries both time and money. On top of that, it also helps reduce waste. All this makes it an expensive, but necessary investment. This is especially true for industries with small to medium-scale productions which have suffered a shortage of workers in recent years.

Some alternative solutions like the Robotic Welding Assistant have a better ROI for smaller productions that would like to automate more. It’s a collaborative solution that saves industries from hidden costs and it is ready to install and start-up.

Robotic Cutting:

Robotic cutting allows for high precision and higher quality cuts, irrespective of the complexity of the cutting blueprints. Some of the technologies used for robotic cutting are laser, plasma, waterjet, and others. Robotic cutting helps workers avoid working with high temperatures cutting and they even accelerate the process.

Robotic cutting is currently used mostly in the automotive, electronics, and sheet metal industries.

Robots are contributing more and more to the industrial revolution by doing mundane and repetitive work. In this blog, we only discussed a few Robotic Applications. There are many other robotic possibilities for the metal industry such as assembly, machine-tending, and quality checks. That last one is especially pertinent in a manufacturing industry of the automotive sector. With the development of Artificial Intelligence (AI), robot’s capabilities are increasing. The horizon is still expanding and there is still much more to go until we can maximize the usage of robots.

References

• automation, B. (2021, 07 06). the application of robots in standard industrial tasks. (BP automation) Retrieved from https://bpautomation.com/the-application-of-robots-in-standard-industrial-tasks/
• system, g. (n.d.). How Robotic Deburring Contributes to Productivity and Delivers ROI for Manufacturers. (genesis system) Retrieved 07 06, 2021, from https://www.genesis-systems.com/blog/how-robotic-deburring-contributes-to-productivity-and-delivers-roi-for-manufacturers
• system, g. (n.d.). Robots in Automotive Manufacturing: Top 6 Applications. (genesis system) Retrieved 07 06, 2021, from https://www.genesis-systems.com/blog/robots-automotive-manufacturing-top-6-applications
• Shake, M. (2021, 07 06). Ten Popular Industrial Robot Applications. (JABIL) Retrieved from https://www.jabil.com/blog/ten-popular-industrial-robot-applications.html
• Reed, B. (2017, 12 13). Complete Guide to Robotic Welding. Retrieved from https://www.fairlawntool.com/blog/complete-guide-robotic-welding/
• Robotics, D. (2021, 07 06). Robotic Deburring cell. (DIY Robotics) Retrieved from https://diy-robotics.com/robotic-deburring-cell/

Thanks to the first section of this blog, we know that part-entry accessories are a great complement to an industry’s automation because they make it more profitable.

Next, we will look at part entry accessories when bulk feeding is not an option, and when a feeding mechanism is not restricted by the shape and size of the parts. So let’s get into it:

The Drawer:

We know what a drawer is in our kitchen house, and this drawer system is based on the same principle. An operator opens the drawer, feeds the part in before closing it to give it to the robot. Then, the robotic arm from the other side of the drawer collects the part, processes it, and puts it back. Drawers can be used for parts of all shapes and sizes. It is a perfect solution for offline productions that require the loading of parts by one or many operators.

It is important to consider the robotic process before choosing this option. Multiple drawers can allow more efficiency and reduce downtime. That kind of configuration allows the robot to work on one drawer while the other is in the loading process by the operator.

Benefits:

• Can house a vast range of products
• Multiple customizable options (single or double)
• Allows operator to work simultaneously on different drawers
• Allows uninterrupted continuous production
• Isolates the operator from the machine’s working space
• Isn’t dependant on the parts’ geometrical symmetries

Some of the industries that use this feeder are metal, plastic, automotive, electronics, and pharmaceutical. Both single and double options are well known among industries.

Get a drawer for your DIY Robotics cell with the Lightbeam add-on.

The Rotative door:

This Rotative door allows operators to add or remove parts from the robot’s secure working space. These doors are helpful as they give operators uninterrupted access to the machine and can allow them to work simultaneously with the robot each on their own side of the door. This makes the part entry really quick and efficient. The selection of this part entry accessory depends on factors like operator safety, part shape and size, and production cycle time.

Benefits:

• Used across variable part dimensions
• Allows simultaneous work for both operator and machinery

• Efficient and cost-effective solution
• Safe for operators

All this makes it ideal for machinery maintenance and ensures secure access for the operator. Rotative doors are used in the automotive industry, metal industry, plastic industry, and many more.

Get a rotative door for your DIY Robotics cell with the Orbit add-on.

The Conveyor:

Conveyors are long moving tracks made of various materials (belt, roller, o’ring, air, etc.) that transfer parts from point A to B. The belts can be made of rubber, metal, plastic and can even be slotted. The selection of this accessory depends on the job the conveyor does and the requirement of the part. For example, if a certain number of finished parts need to be packed, a cleat conveyor can drop the finished parts from the slot into the packaging material. If any raw material needs to be taken to another level, a rubber conveyor could be chosen for better traction, a metal conveyor for spiral inclination, or a slotted one to separate the parts. The most important advantage of this part-feeding technology is that it can be used for any part irrespective of its shape, structure, orientation, weight, or material. This makes it popular across a vast array of industries.

Benefits:

• High-speed feeding system
• Compatible with most robots and machines
• High accuracy and durability

• Low, easy maintenance
• Orientation does not affect feeding
• Low-cost material handling

This technology is used in a wide range of applications such as, marking and coding, packaging, material handling, robotics, assembly, rubber, and many more. 

SMEs can use these part-entry accessories for their changing production lines and gain a competitive advantage over larger industries.

SMEs should consider investing in part-entry accessories as it allows them to utilize their labor force more efficiently and increase their production throughput by automation. This one-time investment can help gain long-term profits and reduces the ROI time slab.

Contact us for more information about the part-entry accessories that best suit your needs.

References

•  D. Robotics, “Products,” DIY ROBOTICS, 18 06 2021. [Online]. Available: https://diy-robotics.com/products/options/.
• Q. Conveyors, “conveyors for automation,” QC Conveyors, 05 07 2021. [Online]. Available: https://qcconveyors.com/conveyors/automation-series/as40/.

According to the RIA (Robotic Industry association), in 2016, 34,606 robots were installed in North America alone. The main purpose of having robots in an industry is to reduce laborious, repetitive, and dangerous tasks. But to perform what they are intended to do, robots need material and parts to be fed in. This is where part entry accessories come into play. Automating this step helps industries utilize their workforce in other, more productive work.

What is a part entry accessory?

As the name suggests, part entry accessories are used to enter raw materials into the assembly line and fetch the finish parts. They are mainly used for inline production to present parts in a specific orientation to the automated machine.

These robot accessories are required when the robot uses bulk parts that need to be presented in a specific orientation. Using these accessories reduces downtimes, the risks for operators, and part mishandling.

Let’s go through some of the most common part entry accessories:

Vibratory feeder bowls:

These vibratory feeder bowls are self-sufficient feeder systems customized according to the supplied part. They comprise a bulk hopper, vibratory mechanism, feeder bowl, a controlling system, and a vibrating track to present the parts to the robot. Parts are fed into the bowl via a hopper and moved across the outfeed track to the part outlet. They can usually sort and process up to 45 to 60 parts per minute. It is used in assembly lines to feed a machine with small randomly sorted individual parts oriented in a particular direction.

Before choosing this option, it’s important to consider the size, the mechanical structure, and the behavior of the parts that will be handled. The reason for this is that vibratory feeder bowls are best suited for symmetrical geometry parts to ensure a specific alignment. When in function, the part moves from the bulk hopper to the bowl, and then, the part to be fed passes through the outlet and is delivered to the desired location.

Benefits:

• Cost-effective
• Variable feed rate
• Customizable bowl
• Different working mechanisms to suit the requirements
• Fewer product damages
• High efficiency and repeatability
• Bulk part possible

This makes it popular in various industrial sectors: automotive, pharmaceutical, electronics, metal works, and many more, and for products such as screws, nuts, food packets, raw material for glass, etc.

Flexibowl:

The name itself reveals a lot about the feeding system. Instead of using a vibratory method, the Flexibowl segregates the parts using a servomotor that can go in both directions, and an impulse generator. It is perfect for irregular parts irrespective of their dimensions. When separated, parts are collected by the robot using a vision system to locate the parts.  The Flexibowl allows three simultaneous activities: dropping, sorting, and picking. It can feed up to 80 parts per minute and it is perfect for production lines with quick products changes.

Before choosing this part-entry solution, it’s important to consider the dimension and the geometry of the parts, the material, and the resistance

Benefits:

• High throughput
• Reliable and efficient
• Low maintenance
• Quick product changeover possible

• Easy to install
• Bulk feeder allows multiple parts feeding
• Possibility of having 2 different parts in the same bowl

This type of feeder accessory is ideal for non-rigid materials, electrical components, and irregular parts. It is widely used in industries like cosmetics, automotive, and medical.

Flexible Feeding System (vibrating table):

This system is basically a table or a disc that, unlike vibratory bowls or Flexibowls, vibrates in all three directions to re-orient the parts. After that, a robotic arm fitted with a camera picks up the correctly oriented parts from the vibrating table and places them in the desired place. This part feeding system is compatible with 99% of parts irrespective of their complex structural geometry or materials. This flexible feeding system works on the principle of 3-axis vibration technology allowing a high efficiency, a maximum orientation change, and minimum damage to the parts.

Even if this solution is really versatile, it’s important to consider the size and the geometry of the parts to handle before choosing a vibrating table.

Benefits:

• Compatible across various product ranges
• Quick product changeover
• Delicate handling of parts
• Reliable and durable

• Accurate part identification
• Easily configurable
• Organized part orientation

This accessory is widely used in various industries from electronics to watchmaking and medical.

Even though the part entry accessories discussed above are in one way or another dependent on the mechanical structure of the part they feed, they increase the production throughput and allow better time management. Thus, even if these above-mentioned part-feeding accessories are famous in the industry, there are various kinds of part feeders available on the market. The ones named in this blog are just a few.

Stay connected to be the first to read our Part Entry Accessories for Robotic Cells  – part 2 in a few weeks.

References

• D. Robotics, “Products,” DIY ROBOTICS, 18 06 2021. [Online]. Available: https://diy-robotics.com/products/options/.
• EAM, “How Vibratory Bowl Feeders Work & What They’re Used For,” EAM, 25 03 2020. [Online]. Available: https://www.eaminc.com/blog/how-vibratory-bowl-feeders-work/.
• R. automation, “What is a bowl feeder? How does it work?,” RNA automation, 06 08 2014. [Online].
• SWOER, ” Vibratory Bowl Feeder,” SWOER, 06 07 2021. [Online]. Available: https://www.swoer.com/vibratory-bowl-feeder/industrial-electrical-vibratory-bowl-feeder.html?gclid=CjwKCAjw_o-HBhAsEiwANqYhp24cwzACAmL_gPtGhLZZ6S11UtB94Qk2JHLcWoIieXCg-T8tyK5DCRoCuR8QAvD_BwE.
• I. Automation Devices, “Vibratory Bowl feeders,” Automation Devices, Inc., 06 07 2021. [Online]. Available: https://www.autodev.com/vibratory-feeder-bowls/?gclid=CjwKCAjwz_WGBhA1EiwAUAxIcUs-sEJb1zaoiwET7HzBYN0MtliMGXzYvdNwbc9VB6wVMd04RDkvYBoCyKwQAvD_BwE .
• Flexibowl, “Flexible Part Feeding Systems: The Benefits,” Flexibowl, 14 03 2020. [Online]. Available: https://www.flexibowl.com/flexible-part-feeding-systems-benefits.html.
• asryil, “Asycube Series – 3-Axis Vibration Robotic Parts Feeder,” asryil- flexible part feeding systems, 05 07 2021. [Online]. Available: https://www.asyril.com/en/products/asycube-flexible-feeders.html.
• Q. Conveyors, “conveyors for automation,” QC Conveyors, 05 07 2021. [Online]. Available: https://qcconveyors.com/conveyors/automation-series/as40/.

Haven’t most of us, during childhood, once hoped for a robot that could pick up our toys, place them back and organize them so that our parents wouldn’t scold us for making a mess? Today, it has become reality. Although robots are not yet picking and placing items in our homes, they are doing so in our factories.

Let us try to expand our horizons, by understanding pick and place robots.

What? How?

A robot that is used to pick items, place them in a desired spot, and in a desired manner is called a pick and place robot. Commonly used in modern manufacturing environments, pick and place robots automate and speed up the process of picking up and placing items in their location. Pick and place robots accomplish all repetitive tasks and help in increasing the production rate.

Types:

There are several types of pick and place robots. They vary depending on their arm extension and the work that they are supposed to accomplish:

Articulated

This is one of the most common varieties of pick and place robots. They come in two different variations: 5-axis and 6-axis. 5-axis robots do not have complete freedom, whereas 6-axis robots do. This allows them to efficiently accomplish complex tasks and easily orientate parts in different axes.

Cartesian

The Cartesian robot is also known as the Gantry robot. It comes with three prismatic joints and axes that coincide with the cartesian coordinates. They are easy to program, easy to use, and have a cubical workspace. Due to their high speed, they are one of the most famous industrial pick and place robots.

Collaborative Robots

Collaborative robots are safe for humans and thus, can share a workspace. Their safety sensors, safety features, rounded edges, limited speed and force make them safe for humans to be around. They can do simple tasks such as pick and place or complex tasks such as material sorting with different payloads.

Delta

With its state-of-the-art vision sensors that identify and sort objects, this is one of the most advanced types of pick and place robots. These robots achieve high speeds thanks to their unique dome-shaped workspace envelope. They are usually mounted over conveyors for better positioning and mobility.

Scara Robots

Selective Compliance Articulated Robot Arm (SCARA) move in all three dimensions (X, Y, and Z) and even have rotatory motion. They are four axes robots and lack the twist and swing from the six axes robots. They have a cylindrical workspace, mostly contained in the front and the sides, with some exceptions on the backside. They are one of the fastest types of robots and therefore used when the reduced cycle times are critical. Best used for pick and place, but also very useful for screw driving and dispensing applications.

Why and where to use Pick and Place Robots?

Pick and place robots are used for different applications and, as they are flexible, can be changed from one station to another on the production line within no time. Some of their applications are:

Assembly

Packaging

Material sorting

Inspection 

The main reasons to use pick and place robots are to reduce laborious and repetitive tasks for humans, and speed up the production process. As per a study by OSHA (Occupational safety and health Administration), pick and place robots help in overcoming musculoskeletal disorders that account for nearly 33% of all work injuries.

With only minor changes, the same robot can be used to perform various operations. This being said, their dimension, movement, and product handling end effector do limit them. Thankfully, they require minimal maintenance despite their sophisticated technology. As they are more cost-effective than other automation technologies on the market, pick and place robots enable companies to gain a competitive advantage and maximize productivity.

References

• DIY-Robotics, “Astro 33,” DIY robotics, 30 05 2021. [Online]. Available: https://diy-robotics.com/products/astro-33/.
• GRANTA, “What Are The Different Types of Pick and Place Robots?,” Granta, 18 2 2018. [Online]. Available: https://www.granta-automation.co.uk/news/what-are-the-different-types-of-pick-and-place-robots/.
• M. C. robotics, “delta robots are healthy alternatives,” motion control robotics, 30 05 2021. [Online]. Available: https://motioncontrolsrobotics.com/delta-robots/.
• W. Allen, “What is a pick and place robot?,” 6 River systems, 22 02 2021. [Online]. Available: https://6river.com/what-is-a-pick-and-place-robot/.