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As more industries are moving into Industry 4.0, they are looking for new innovative ways to improve their production through the use of robotics. However, for industries which already possess robotic equipment, there are a few solutions available to further improve their efficiency. One of these solutions is through the use of robotic cells.

Also known as a work cell, a robotic cell is defined as a closed workspace where one or more robots are installed. The purpose of these cells is to increase the efficiency of the robot while still maintaining a safe work environment for nearby employees. This is accomplished by ensuring no employee can interact physically with the robot unless the system is shut down, to which the doors of the cell would unlock. When a robot is confirmed to present no hazards to nearby human workers, speed restrictions can be lifted to allow the robot to work faster and provide high productivity.

There are a range of robotic cells which are available to any industry. Cells can be integrated alongside individual or multiple robots in a production atmosphere. This could be as simple as ordinary barriers around an entire robotic collection, or specialized cells with controls and programming capabilities. Each industry or production floor will have certain constraints for acceptable robotic cells; this is dependent on the size, weight, or type of robots used. Therefore, it is important to select one capable of supporting the robotic equipment you plan to use with it.

At DIY Robotics, robotic cells are our specialty. We offer a range of robotic cells each with its own benefits and types of robots it can house (based on weight and size), as specified on our product page. Our cells can be categorized into two groups, collaborative and modular cells.

Collaborative cells are designed to work with or close to human workers. These cells have speed limitations to ensure the robot does not harm an employee and are great at performing various tasks. Collaborative robots are an excellent addition to small and medium industries looking for an adaptable robot. Our modular cells provide a closed workspace and are well suited for working with other machines or robots. All of our cells each have the benefits stated above, along with a few unique ones:

Customizable

Each of our cells has the potential to be completely customizable to match your workspace layout. This includes offering customizable panels (the walls of the cell) which are specifically tailored to integrate with your surrounding production equipment, as well as the capability to house your own robotic arms. Each of our cells can come equipped with a FANUC robot, or you can use your own.

Mobile

Our cells are designed to be mobile around a workspace. This means that a robot can easily be relocated to any station in the case where a production floor’s layout was to change, or if a problem were to occur with the robot. Traditional robotic equipment is usually bolted to the floor and can result in lengthy installation/removal of the equipment. Our robotic cells will not have that problem. This is accomplished by the industrial-grade locking wheels that are installed onto the robotic cell.

Durable

Our cells are constructed with welded and folded sheet metal to ensure a strong frame for any robot. Our cells make no compromise on the robot’s acceleration and speed due to the strong materials the cell is made of. Due to the strong frame and industrial locking wheels, vibrations or jolts from the robot are not a concern for our cells. All materials the cell is composed of are also scratch and rust-resistant.

Robotic cells bring many benefits to any work environment. Collaborative cells create a safe workspace for humans to interact closely with the robots without harm. Modular robotic cells remove any hazards to which a human worker would be subject to due to the closed workspace, and allows the robot to work faster which will increase efficiency. DIY robotics has a wide range of robotic cells available, each with its own benefits and specifications on the robots it can be integrated alongside. Please feel free to visit our product page to begin customizing your robotic cell for your workspace: https://diy-robotics.com/products/. If you have any other inquiries, please feel free to contact us and we will put you in touch with an expert: https://diy-robotics.com/contact/

References

• Robotic Cell Finder: Products: DIY-Robotics. DIY Robotics. (2022, May 12). Retrieved June 12, 2022, from https://diy-robotics.com/products/

As the world becomes more and more futuristic, industries have been upgrading their machine floors to become more efficient and productive. Automation is seen throughout the manufacturing world and is essential for any business to be on track with Industry 4.0. Many factory processes incorporate automation, one of which includes inspection installations. Automated inspection installations come in different forms, each with their own advantages and disadvantages. The most common inspection technologies include vision systems, measurement sensors, and optical comparators.

This post is part 2 of 3, where we will highlight Measurement Sensor technologies, along with their applications in the industry. The final topic (optical comparators) will be addressed in a final third post. If you are interested in vision systems and their applications, please feel free to visit part one of this series.

A measurement sensor is a device that determines a distance or dimensions of an object based on the readings and signals from an electronic element. Depending on the type of electronic element, a measurement sensor can have several types. These include but are not limited to ultrasonic sensors, contact sensors, laser & optical sensors, and inductive displacement sensors.

Ultrasonic Sensors

One of the more well-known measurement sensors, the ultrasonic sensor uses high-frequency sounds waves to determine the distance to an object. This is accomplished by emitting the sound waves towards the object and starting a timer. The sound waves are then reflected back, the receiver picks it up and stops the timer. The distance is then calculated based on time of travel and speed of sound (constant value in a standard medium). Ultrasonic sensors usually consume minimal power and can be used to measure objects that other sensors could not, such as liquid or transparent surfaces. However, ultrasonic sensors have a low detection range and accuracy compared to other measurement sensors.

Contact Sensors

As the name suggests, this sensor measures the distance of an object by directly contacting it. Contact sensors are usually used for detecting the height, thickness, or profile of an object since it works in one dimension. These sensors are also very durable due to the constant physical movements they are subjected to. They transmit high-precision data, often with a resolution in the micrometers. Contact sensors are especially useful in environments which are subject to water or oil since the sensor relies on a magnetic sensing method.

Laser & Optical Sensors

Laser and optical sensors contain the bulk of measurement sensors; therefore, we will address three technologies in this section. First is the Laser Profiler. This technology uses a sensor and special lensing to produce a laser line rather than a single laser point. This allows for 2D and 3D measurements like height, width, angle, and profile to be recorded using triangulation. This process can be completed at high speeds which makes it an ideal choice for fast-paced environments like a factory assembly line.

Next is the laser displacement sensor. Unlike the laser profiler, the laser displacement sensor concentrates its triangulation to convene at a single point, which results in an extremely accurate reading. A laser displacement sensor is more accurate than a laser profiler, but if a two-dimensional measurement is required, the displacement sensor won’t be as efficient (since it would need to measure the object point by point).

Finally, there is the optical micrometer. This sensor generates a beam of light that encompasses the entire object. As the object moves through the beam, light is blocked from the receiver and it records the measurement of the ‘shadow’. In other words, this sensor would be able to generate the cross-sectional area of an object as it passes through the beam. From there, specific details about the object would be recorded. This includes detecting defects (like cracks or dents), creating a 2D representation, etc. This technology is extremely accurate and is often seen in many manufacturing settings.

Inductive Displacement Sensors

An inductive displacement sensor is a non-contact proximity sensor used for the detection of metal objects. This sensor uses electromagnetic induction to determine the distance of the magnetic object; therefore, non-ferrous metals (which are less magnetic) will not be as effective in sensing. An inductive displacement sensor is made up of a galvanometer which defects its position when a magnet is moved closer to it. Once the magnet is stationary the galvanometer is returned to its original position. When the magnet is pulled away, it defects in the opposite direction. Hence, the sensor will know when the object is moving closer or further away from it. Once the magnet has been calibrated with real-world measurement units, displacement sensing is accomplished.

This concludes the week’s post about robotic inspection installations. Please stay connected for the third and final post where we will address Optical Comparators and their applications in the robotic industry. If you have any questions regarding the material addressed, feel free to contact us and we will put you in touch with one of our experts.

References

• Inductive proximity sensors for special applications. (n.d.). Retrieved January 7, 2022, from https://www.machinedesign.com/automation-iiot/sensors/article/21834877/inductive-proximity-sensors-for-special-applications
• Electromagnetic induction and faradays law. Basic Electronics Tutorials. (2020, February 8). Retrieved January 7, 2022, from https://www.electronics-tutorials.ws/electromagnetism/electromagnetic-induction.html
• Contact sensors. OMRON, Europe. (n.d.). Retrieved January 7, 2022, from https://industrial.omron.eu/en/products/contact-sensors
• What is the difference between laser displacement sensor and laser profile sensor? (n.d.). Retrieved January 7, 2022, from https://www.pomeas.com/download/2021/5/11/what-difference-between-laser-displacement-sensor-and-laser-profile-sensor/
• Optical micrometer / digital micrometer. KEYENCE. (n.d.). Retrieved January 7, 2022, from https://www.keyence.ca/products/measure/micrometer/

The manufacturing environment is defined by its ability to manufacture goods using assembly lines and machines. Factories should have the main intent to reduce costs, increase production efficiency, and reduce hazards. This can be achieved by integrating robotic automation within their production process. In order to achieve true automation, however, a robot needs to know what it is working with, along with its physical measurements in order to perform its instructed tasks. Such applications include but are not limited to identification, measurement, positioning, flaw detection, etc. This can be done through the use of robotic inspection, or machine vision. Machine vision uses sensors and software algorithms to complete visual tasks and guide the equipment during product assembly.

There are different technologies available for automated measuring/inspection installations. Each of them with its own advantages and disadvantages based on the environment they are subject to. It is important to understand that the technology chosen is dependant on the material/object under inspection. Below is a list of the most commonly used inspection technologies:

• Vision Systems
• Measurement Sensors
• Optical Comparators

This week’s post will be part 1 of 3, where we will highlight the capabilities of Vision Systems and their applications in the industry. The remaining topics will be discussed in posts to come.

Vision systems use your typical sensors to detect if an object is present. If the sensor is triggered, a camera will capture an image. Then, depending on the machine’s software, it will determine whether or not machine instructions will take place based on the reference image captured. Depending on the application, manufacturers have two choices with regards to vision systems: 2D or 3D.

2D machine vision uses a camera to capture images of an object and can detect variations in contrast. Applications that involve 2D vision systems can include label orientation, barcode reading, defect detection, pattern or color inspection, etc. 2D vision systems are well known in the automation industry for their simple and effective inspection capabilities. As you would expect, 2D machine vision limitations include ambient lighting, contrast variations, and parallax. 

3D vision systems are capable of sensing the height of an object. This type of vision system has multiple ways to create a 3D image. These include the use of multiple cameras which splice images together, structured light projectors which sense optical patterns and captures an ideal image, and laser triangulation to follow the profile of an object and create a digital geometry. Recently, manufacturers have begun to use 3D machine vision more due to its more accurate dimensional data. By using 3D vision, a robot can also sense variations in its physical environment and adapt accordingly. This feature is extremely useful for bin picking robots where objects are in random poses located in a container like a box. Hence, the majority of industrial robots work in the three-dimensional world.

Vision Systems are very capable of performing robotic guidance. By using the processes stated above, guidance systems can locate the position and orientation of a part, and compare it to a tolerance that takes into account the contrast, lighting, scale, rotation, etc. In other words, 2D and 3D systems can locate an object anywhere within the vision range of the camera, and perform programmed robotic instructions accordingly.

A few benefits vision systems present are listed below:

Reduced Defects
Vision systems have the capability to notice when there are errors or discrepancies between products. This could include incorrect physical structure (damaged or manufactured wrong), mislabeling of the products, etc. These errors cost manufacturers money when needing to replace or recall product.

Increased Production
Some manufacturing environments still rely on human inspection of products. With automated vision systems, products can be accurately inspected. This will save time and money while still maintaining a strict schedule. Vision systems can also increase efficiency by analyzing products as they move down production lines. An example could be as a product comes off the assembly line, it may be in different position orientations. Through machine vision, and the correct software, a machine would know where to grab or position the product to correctly manufacture or package it.

That concludes the content for this week’s post on Robotic Inspection Installations. In later posts, we will touch on the remaining two topics stated above. Please feel free to contact us regarding any of the stated material, or if you have questions about our products: https://diy-robotics.com/contact/.

References

• “3D Machine Vision.” STEMMER IMAGING, https://www.stemmer-imaging.com/en/knowledge-base/3d-machine-vision/.
• “An Introduction to Machine Vision and the Machine Vision System.” An Introduction to Machine Vision and the Machine Vision System, https://www.thomasnet.com/articles/automation-electronics/machine-vision-systems/.
• Vision sensors. KEYENCE. (n.d.). Retrieved February 1, 2022, from https://www.keyence.ca/products/vision/vision-sensor/.