window.dataLayer = window.dataLayer || []; function gtag(){dataLayer.push(arguments);} gtag('js', new Date());gtag('config', 'UA-141884085-1'); gtag('config', 'AW-761820283');

Cobot

Building the future: Addressing challenges with industrial and collaborative robotics in plastics manufacturing

The plastics industry faces significant challenges in maintaining competitiveness in the market. Some of these challenges can be effectively addressed through the integration of industrial and collaborative robotics. This article explores the main issues and future prospects for operations management in this dynamic sector, focusing on how robotics is reshaping manufacturing processes to meet these challenges head-on.

DAILY CHALLENGES: STREAMLINING WITH ROBOTICS

Production delays and inefficiencies

In the hectic environment of a plastic manufacturing plant, maintaining smooth production without interruptions is a monumental task. For instance, if a machine breaks down or an operator calls in sick, the entire production line can face delays, affecting the plant’s ability to meet delivery deadlines. This is where industrial robots shine. Capable of working tirelessly around the clock, robots ensure a consistent production rate, minimizing interruptions. For example, the integration of robot arms that handle repetitive tasks like moving molds parts between processing stations can prevent time wastage and enable a faster production turnover, directly addressing inefficiencies and enhancing workflow.

Workforce constraints and skill shortages

The scarcity of skilled labor in the industry is another significant obstacle. Consider a scenario where a high-demand order is received, but the plant is understaffed due to a lack of qualified workers. Training new employees in time-sensitive situations may not always be viable. Robots can fill these gaps by taking over repetitive and hazardous tasks, such as handling hot plastic parts straight from the injection molding machines. This frees up human workers to engage in more value-added activities like process optimization and creative problem-solving. Imagine a collaborative robot (cobot) working alongside operators to manage material handling, effectively creating a partnership that maximizes human talent while the robots handle drudgery.

Maintaining quality and consistency

Ensuring that every product meets exacting quality standards can be a daunting challenge with human operators, especially over long shifts where fatigue sets in. For example, manual quality inspections can miss minute defects, leading to inconsistent product batches. Robotic systems bring unparalleled precision and consistency to the table. Industrial robots equipped with advanced vision systems can conduct detailed, real-time quality checks during the manufacturing process. For instance, a robot can monitor injection molding processes and immediately identify defects, ensuring that only top-quality products proceed to the next production stage. This level of accuracy not only reduces waste and rework but also ensures that you consistently deliver high-quality products to your clients.

Safety and workplace injuries

The risk of injury in plastics manufacturing is a significant concern, with workers often exposed to high temperatures, sharp objects, and heavy machinery. For example, operators manually loading and unloading parts or inserts in injection molding machines can result in severe injuries. By deploying robots to handle dangerous and physically demanding tasks, these risks can be dramatically reduced. Robots can autonomously manage the loading and unloading of parts from hot molding machines, ensuring human operators remain safe and focusing on oversight roles rather than direct physical involvement. This transition not only enhances workplace safety but also reduces costs associated with medical leaves and accident claims.

Unplanned downtime and maintenance challenges

Unanticipated equipment breakdowns can halt an entire production line, consequently leading to expensive downtimes. Suppose a critical molding machine fails during peak production hours; the delays can be costly and disruptive. With robotics, predictive maintenance becomes feasible. Robots fitted with IoT sensors can continuously monitor machine health, predicting and alerting maintenance teams about potential failures before they occur. This enables timely interventions to prevent breakdowns. Additionally, robotic machines themselves are designed with high reliability and minimal maintenance needs, further reducing operational disruptions.

APPLICATIONS OF ROBOTICS IN PLASTICS MANUFACTURING

The integration of robotics into plastics manufacturing is revolutionizing production lines by enhancing efficiency, consistency, and safety. Robots can be employed in various stages of the production process, from machine tending to post-processing, offering significant improvements in productivity and quality. 

  • Machine tending: Robots can load and unload injection molding machines, reducing the risk of injuries to workers and improving production consistency.
  • Insert molding: Robots can efficiently handle tasks like adding inserts to moldings and loading them into machines.They are faster, which reduces cycle times and increases profitability.
  • Overmolding: Six-axis robots can automate the overmolding process, reducing labor and assembly expenses while ensuring product quality.They also speed up production, lowering cycle times and boosting profitability.
  • In-mold labeling: Robots can perform precise in-mold labeling, enhancing the efficiency and accuracy of this process.
  • Post-processing: Robots can handle various post-processing tasks such as inspection, testing, and hot-stamping of plastic molded parts.

CASE STUDY OF ONE OF OUR DIY OFFICIAL INTEGRATOR: CFM ROBOTIQUE

Initial need:

A global Tier 1 supplier in the automotive industry approached our DIY Official Integrator and sought to optimize their overmolding process, specifically involving the overmolding of a plastic insert with EPDM. The client’s existing setup required 12 operators to meet the cycle times and annual production volumes.

The customer needed to maintain precise cuts on a lip with a few thousandths of an inch tolerance. This task required a level of craftsmanship that was difficult to sustain consistently and efficiently with manual labor. The goal was to reduce the reliance on a large number of operators while achieving the required precision and improving overall efficiency.

Challenges:

  1. Production delays and inefficiencies: The reliance on 12 operators led to frequent delays due to manual errors and the need for meticulous precision, which slowed down the production process.
  2. Workforce constraints and skill Shortages: High turnover rates and the need for constant recruitment and training of skilled operators were costly and time-consuming.
  3. Maintaining quality and consistency: Manual cutting struggled to consistently meet the required precision, leading to quality issues and inconsistent product batches.
  4. Safety and workplace injuries: Operators handling knives faced significant risks of injuries, contributing to higher medical costs and lost workdays.
  5. Unplanned downtime and maintenance challenges: The manual nature of the process led to frequent unplanned downtime due to operator fatigue and equipment maintenance issues.

Solution:

Our Official Integrator implemented a solution using two Comet 44 robotic cells equipped with laser cutting technology. This automated the precise cutting task, significantly reducing the need for manual intervention.

Results:

  1. Optimizing production efficiency and timeliness: The automation of the cutting process with robotic cells eliminated manual errors and significantly reduced cycle times, leading to a smoother and more efficient production flow.
  2. Empowering workforce and enhancing skills: The implementation of robotic cells reduced the need for 6 operators, minimizing the challenges associated with high turnover rates, recruitment, and training costs.
  3. Ensuring high quality and consistency: The laser cutting robots provided unparalleled precision and repeatability, achieving an Overall Equipment Effectiveness (OEE) of 98%. The quality level, previously unattainable with manual labor, was consistently met.
  4. Promoting workplace safety and well-being: With robots handling the cutting tasks, operators no longer need to use knives, significantly reducing the risk of injuries and musculoskeletal issues.
  5. Maximizing uptime and streamlining maintenance: The reliable performance of the robotic cells minimized unplanned downtime and reduced maintenance challenges, ensuring continuous production.

Financial impact:

The initial investment of $300,000 USD for 2 laser robotic trimming cells resulted in an estimated savings of $900,000 USD over three years. This substantial return on investment was achieved through reduced labor costs, improved quality, and enhanced operational efficiency.

CONCLUSION

The integration of industrial and collaborative robotics in the plastics industry offers significant opportunities for improving efficiency, quality, and competitiveness. However, it also presents challenges that operations managers must address, including initial investment costs, workforce adaptation, and ongoing maintenance.

As the robotics market continues to grow, manufacturers should consider leveraging automation for their plastic injection-molding operations to keep pace with rapidly changing market demands and maintain a competitive edge.

Facing production challenges? Elevate your manufacturing line with DIY solutions

Are you encountering inefficiencies or production delays? Transform your manufacturing operations with our cutting-edge DIY resources. Discover how our tailored solutions can address your unique challenges and drive your production line to peak performance.

Ready to take the next step?

Book a meeting with us today and let’s discuss how we can support your automation journey and enhance your operational efficiency.

Exploring the Levels of Collaboration and Industrial Scenarios with Cobots: A Comprehensive Guide

Collaborative robots have revolutionized the manufacturing industry by offering a new level of flexibility and efficiency. Unlike traditional industrial robots that are solely designed to work in isolation, cobots are specifically designed to work alongside humans in a collaborative manner. This opens up a wide range of possibilities for automation in various industrial scenarios. In this comprehensive guide, we will explore the different levels of collaboration and industrial scenarios where cobots are commonly used.

Understanding the levels of collaboration in cobots

Cobots are classified into different levels of collaboration based on their interaction with humans. Each level represents a different degree of collaboration and safety features. Understanding these levels is crucial for choosing the right cobot for your specific needs. Here are the levels we will explore :

  • Level 1: Safety monitored stop
  • Level 2: Hand guiding
  • Level 3: Speed and separation monitoring
  • Level 4: Power and force limiting
  • Level 5: Safety-rated monitored stop
  • Level 6: Hand guiding with speed and separation monitoring
  • Level 7: Power and force limiting with speed and separation monitoring

Level 1: Safety monitored stop

At level 1, cobots are equipped with safety sensors that can detect the presence of humans in their workspace. When a human enters the cobot’s workspace, it will automatically stop its operation to prevent any potential accidents. This level is suitable for scenarios where human interaction is minimal, and the primary goal is to ensure the safety of the human workers.

Level 2: Hand guiding

Level 2 cobots allow direct physical interaction between humans and robots. They have sensors that can detect and respond to human touch, allowing operators to guide the cobot’s movements manually. This level of collaboration is ideal for tasks that require precise positioning or delicate handling.

Level 3: Speed and separation monitoring

At level 3, cobots can work in close proximity to humans while constantly monitoring their speed and separation. If the cobot detects that a human is moving too fast or getting too close, it will automatically slow down or stop to maintain a safe distance. This level of collaboration is suitable for scenarios where humans and cobots need to work side by side, such as assembly lines or material handling.

Level 4: Power and force limiting

Level 4 cobots are designed with advanced safety features that limit the amount of force and power they can exert. This level of collaboration enables cobots to work in direct contact with humans without posing any risk of injury. It is commonly used in applications that require forceful tasks, such as heavy lifting or machine tending.

Level 5: Safety-rated monitored stop

Similar to level 1, level 5 cobots have safety sensors that can detect the presence of humans. However, they also have additional safety features, such as safety-rated monitored stop, which ensures that the cobot stops its operation in a safe manner. This level of collaboration provides an extra layer of safety for scenarios where human workers are more involved in the cobot’s operation.

Level 6: Hand guiding with speed and separation monitoring

Level 6 cobots combine the features of level 2 and level 3. They allow operators to manually guide the cobot’s movements while also monitoring the speed and separation between humans and cobots. This level of collaboration is suitable for tasks that require both precision and close human-robot interaction.

Level 7: Power and force limiting with speed and separation monitoring

At level 7, cobots have the combined features of level 4 and level 3. They can work in direct contact with humans while ensuring both power and force limitation and monitoring the speed and separation. This level of collaboration is ideal for applications that require both forceful tasks and close human-robot collaboration.

Industrial scenarios where cobots are used

Cobots are widely used in various industrial scenarios due to their ability to enhance productivity and safety. Let’s explore some of the most common scenarios where cobots are employed.

Scenario 1: Assembly line automation

In assembly line automation, cobots play a vital role in speeding up the production process. They can perform repetitive tasks, such as picking and placing components, tightening screws, or performing quality checks. Cobots at different levels of collaboration can be used depending on the complexity of the assembly process and the required level of human involvement.

Scenario 2: Material handling and logistics

Cobots are excellent for material handling and logistics applications. They can efficiently move heavy objects, load and unload pallets, and transport goods within a warehouse or distribution center. Cobots with different levels of collaboration can be utilized to optimize the workflow and reduce the risk of injuries associated with manual material handling.

Scenario 3: Quality control and inspection

Ensuring product quality is crucial in manufacturing. Cobots can be programmed to perform precise quality control and inspection tasks, such as measuring dimensions, detecting defects, or conducting visual inspections. With their high accuracy and repeatability, cobots can significantly improve the quality control process.

Scenario 4: Welding and fabrication

Cobots are increasingly being used for welding and fabrication tasks. They offer increased precision and speed compared to manual welding, resulting in higher productivity and improved weld quality. Cobots equipped with appropriate safety features can work alongside human welders, reducing the risk of accidents and enhancing overall efficiency.

Scenario 5: Packaging and palletizing

In packaging and palletizing applications, cobots can automate the process of packing products into boxes or loading them onto pallets. They can handle different types of products and adapt to varying packaging requirements. Cobots with different levels of collaboration can be employed depending on the complexity of the packaging process and the need for human intervention.

Scenario 6: Machine Tending

Cobots are well-suited for machine tending tasks, where they can load and unload parts from machines, perform tool changes, or monitor the production process. By automating machine tending, manufacturers can improve productivity, reduce errors, and free up human workers for more complex tasks.

Conclusion: Choosing the right level of collaboration and industrial scenario for your business

As the use of cobots continues to grow, it is essential for businesses to understand the different levels of collaboration and industrial scenarios that best suit their specific needs. Whether it is assembly line automation, material handling, quality control, welding, packaging, or machine tending, cobots offer a range of solutions to enhance productivity, safety, and efficiency. By carefully considering the levels of collaboration and industrial scenarios required, businesses can leverage the power of cobots to stay competitive in today’s rapidly evolving manufacturing landscape.

If you’re interested in exploring the potential of cobots for your business, contact us today for a consultation and discover how cobots can revolutionize your manufacturing processes.

Revolutionizing Industrial Efficiency: How Cobots Are Solving Manufacturing Challenges

In the ever-evolving world of manufacturing, new technologies are constantly emerging to improve efficiency and productivity. One such technology that has gained significant traction in recent years is collaborative robotics, often referred to as “cobots”. Cobots are designed to work alongside humans, assisting them in various tasks and revolutionizing the manufacturing industry. Unlike traditional industrial robots, which are typically designed to work in isolation, cobots are built with advanced sensors and programming that allow them to interact and collaborate with human workers.

The challenges in traditional manufacturing processes

Traditional manufacturing processes often face a myriad of challenges that can hinder productivity and efficiency. One of the major challenges is the need for repetitive and mundane tasks that are not only time-consuming but also prone to errors. These tasks, when performed by human workers, can lead to fatigue and decreased motivation, which in turn affects the overall quality of the products. Additionally, traditional industrial robots, while efficient in certain tasks, lack the ability to adapt to dynamic environments and work alongside humans seamlessly.

How cobots are revolutionizing the manufacturing industry

Cobots are transforming the manufacturing industry by addressing the challenges faced in traditional manufacturing processes. With their ability to work collaboratively with human workers, cobots are streamlining production lines, improving efficiency, and reducing errors. These robots can take on repetitive and mundane tasks, allowing human workers to focus on more complex and value-added activities. Cobots can also be easily programmed and reprogrammed to adapt to changing production needs, making them highly flexible and versatile.

Another key advantage of cobots is their ability to enhance the safety of manufacturing operations. The advanced sensors and safety features in cobots enable them to detect the presence of humans and adjust their movements accordingly, minimizing the risk of accidents and injuries. This collaborative nature of cobots ensures a harmonious working environment where humans and robots can work side by side without compromising safety.

Benefits of using cobots in manufacturing

The adoption of cobots in manufacturing comes with a multitude of benefits. Firstly, cobots significantly increase productivity by reducing cycle times and optimizing resource utilization. With their ability to work 24/7, cobots can operate continuously without the need for breaks or rest, leading to higher production output. Moreover, cobots can perform tasks with precision and consistency, resulting in improved product quality and reduced waste.

Cobots also offer cost savings for manufacturers. Compared to traditional industrial robots, cobots are more affordable, making them accessible to small and medium-sized enterprises. Additionally, cobots require minimal infrastructure and can be easily integrated into existing production systems, eliminating the need for major facility modifications. With their user-friendly interfaces and intuitive programming, cobots can be operated and maintained by existing staff, reducing the need for specialized training and additional workforce.

Implementing cobots in your manufacturing facility

Integrating cobots into your manufacturing facility requires careful planning and consideration. Firstly, it is essential to identify the tasks that can be automated and benefit from cobot collaboration. Conduct a thorough analysis of your production processes to determine which tasks are repetitive, time-consuming, and prone to human error. Once identified, these tasks can be assigned to cobots, freeing up human workers for more complex and critical activities.

When implementing cobots, it is important to provide proper training to your workforce. While cobots are designed to be user-friendly, training your employees on how to interact and collaborate with cobots will ensure a smooth transition and maximize the benefits of cobot integration. Additionally, it is crucial to establish clear safety protocols and guidelines to ensure the well-being of your employees. Regular maintenance and inspection of cobots should also be conducted to ensure optimal performance and longevity.

Training and safety considerations for working with cobots

Working with cobots requires a shift in mindset and approach. Employees need to understand the capabilities and limitations of cobots to effectively collaborate with them. Providing comprehensive training on cobot operation, programming, and troubleshooting will empower your workforce to work alongside cobots seamlessly. It is also important to establish open lines of communication between human workers and cobots, fostering a sense of trust and collaboration.

Safety considerations are paramount when working with cobots. Conduct a thorough risk assessment of your manufacturing processes to identify potential hazards and implement necessary safety measures. This may include installing safety barriers, implementing emergency stop systems, and providing personal protective equipment. Regular safety training sessions should be conducted to ensure that employees are aware of the safety protocols and guidelines when working with cobots.

Future trends and advancements in collaborative robotics

As technology continues to advance, the future of collaborative robotics holds immense potential. The ongoing development of artificial intelligence and machine learning is expected to enhance the capabilities of cobots, enabling them to learn and adapt to new tasks more efficiently. This will further improve productivity and flexibility in manufacturing processes.

Another future trend in collaborative robotics is the integration of cobots with other emerging technologies such as the Internet of Things (IoT) and cloud computing. This integration will enable real-time data exchange and remote monitoring of cobots, allowing for predictive maintenance and optimization of production processes. Cobots will become an integral part of smart factories, contributing to the overall digital transformation of the manufacturing industry.

Conclusion: The Future of Manufacturing with Cobots

Cobots are revolutionizing the manufacturing industry by addressing the challenges faced in traditional manufacturing processes. Their ability to collaborate with human workers, improve efficiency, enhance safety, and reduce costs make them invaluable assets in modern manufacturing facilities. By integrating cobots into production lines and providing the necessary training and safety considerations, manufacturers can unlock the full potential of cobots and pave the way for a more productive and sustainable future of manufacturing.

 

Embrace the power of cobots and transform your manufacturing processes. Contact us today to learn more about how cobots can revolutionize your production lines.

The Future of Welding: Exploring the Impact of Cobots in Robotic Welding

Robotic welding has revolutionized the welding industry, streamlined processes, and increased efficiency. With the advent of automation, welding has become faster, more accurate, and safer. Traditional methods of welding required skilled human operators who were exposed to hazardous conditions. However, with the introduction of robotic welding, the landscape of the industry has changed significantly. In this article, we will delve into the future of welding and explore the impact of cobots in robotic welding.

The Benefits of Robotic Welding

Robotic welding offers numerous advantages that have transformed the welding industry. Firstly, it significantly enhances productivity by reducing welding time and increasing the speed of production. This results in higher output and reduced labor costs. Additionally, robotic welding ensures consistent weld quality, eliminating human errors and inconsistencies. The precision and accuracy offered by welding robots lead to stronger and more reliable welds, ultimately improving the overall quality of welded products.

Furthermore, robotic welding machines provide a safer working environment by removing the need for human operators to be near hazardous welding operations. This reduces the risk of work-related injuries and exposure to harmful fumes and radiation. Moreover, welding robots can operate continuously without the need for breaks, leading to increased operational efficiency and minimal downtime.

The Rise of Collaborative Robots in Welding

Collaborative robots, also known as cobots, are designed to work alongside humans, sharing the same workspace and collaborating on tasks. Cobots in robotic welding are becoming increasingly popular due to their ability to combine the precision and strength of industrial robots with the flexibility and adaptability of human workers. These welding robots are equipped with advanced sensors and software, allowing them to detect and respond to human presence, ensuring safe and efficient collaboration.

The use of collaborative robots in welding offers several advantages. Firstly, it allows for more complex welding tasks that require human dexterity and decision-making skills. By working in tandem with humans, welding cobots can carry out intricate welding operations that would otherwise be challenging for traditional welding robots. Additionally, collaborative welding robots can be easily programmed and reprogrammed by human operators, enabling quick adaptability to changing welding requirements.

How Robotic Welding Machines Work

Robotic welding machines are sophisticated systems that combine mechanical hardware, advanced sensors, and intelligent software to automate the welding process. The key components of a typical robotic welding system include the welding robot, welding power supply, welding torch, and control panel.

The welding robot is the core component responsible for carrying out the welding operation. It is equipped with multiple axes and a robotic arm that can move with precision and accuracy. The welding power supply provides the electrical energy required for the welding process, ensuring a stable and consistent arc. The welding torch, attached to the robotic arm, holds the welding electrode and directs the welding arc to the desired location. Lastly, the control panel allows human operators to program and control the robotic welding system.

The Impact of Collaborative Robots on the Welding Industry

The introduction of collaborative robots in the welding industry has had a profound impact. These robots have not only improved productivity and quality but have also transformed the working environment. By working alongside human operators, collaborative welding robots have created a collaborative human-robot future that maximizes the strengths of both parties. This has led to improved efficiency, reduced labor costs, and increased job satisfaction among human workers.

Moreover, the use of collaborative welding robots has opened new opportunities for small and medium-sized enterprises (SMEs). Previously, only large-scale companies could afford the high costs associated with welding automation. However, collaborative robots offer a more affordable and flexible solution, making welding automation accessible to a wider range of businesses. This has led to increased competitiveness and growth within the welding industry.

Cobots in Robotic Welding

Collaborative robots, also known as cobots, have emerged as a solution to the limitations of traditional welding robots. Unlike traditional robots, cobots are designed to work alongside human operators, rather than replacing them. They are equipped with advanced safety features, such as force sensors and vision systems, which allow them to interact safely with humans. Collaborative robots have the potential to transform the welding industry by combining the strengths of human operators and robots. They can assist human welders by performing repetitive or physically demanding tasks, while the human operators focus on more complex welding operations.

Future Trends in Robotic Welding Automation

While DIY robotics offers numerous advantages, it is important for companies to be aware of the challenges and considerations involved. One of the main challenges is the need for technical expertise. Building and programming robots requires a certain level of technical knowledge and skills. Companies may need to invest in training or hire experts to ensure successful implementation.

This is why DIY Robotics offers DIY ++ services: designed to provide clients with solutions specifically tailored to meet their needs. Whether compagnies require support for 3D printing, electrical engineering, machining, programming, mechanical engineering, or more, DIY Robotics is here to support you.

Our team of experts is well-versed in all of these fields, and we are dedicated to providing clients with the support they need, when they need it. With our DIY++ services, you will have access to a wealth of knowledge and expertise, which will help you achieve your goals more efficiently and effectively.

Training and Skills Required for Working with Welding Robots

As the use of cobots in robotic welding continues to grow, the demand for skilled operators and technicians is also increasing. To work effectively with welding robots, operators need to have a solid understanding of welding principles, programming languages, and operating procedures. Training programs and certifications are available to equip individuals with the necessary skills to operate and maintain robotic welding systems.

Furthermore, collaboration skills are essential when working alongside welding cobots. Operators must be able to communicate and coordinate effectively with the robots to ensure safe and efficient collaboration. This includes understanding the limitations and capabilities of the welding robots and being able to troubleshoot any issues that may arise during the welding process.

Future Trends and Predictions for Robotic Welding

The future of robotic welding looks promising, with several trends and predictions emerging. One trend is the miniaturization of welding robots, allowing them to access tight spaces and perform intricate welding tasks. Another trend is the integration of collaborative features into traditional welding robots, enabling human-robot collaboration to become more seamless. Moreover, advancements in AI and machine learning will continue to enhance the capabilities of welding robots, enabling them to adapt to changing welding conditions in real time. The future of robotic welding is undoubtedly bright, with more industries embracing this technology for improved efficiency and quality.

A Collaborative Human-Robot Future

In conclusion, the future of welding lies in the collaboration between humans and robots. The introduction of collaborative robots in the welding industry has transformed the way welding is done, bringing about increased productivity, improved quality, and a safer working environment. Through successful case studies and advancements in technology, it is evident that the impact of collaborative robots in robotic welding is significant and promising.

As the welding industry continues to evolve, it is crucial for businesses and individuals to adapt to these changes. Embracing robotic welding automation and investing in the necessary training and skills will ensure competitiveness and growth in this rapidly advancing field. By harnessing the strengths of both humans and robots, the future of welding holds endless possibilities for innovation and success.

To explore the world of robotic welding and optimize your welding processes, visit our robotic welding assistant page to learn more about it.

USES OF COLLABORATIVE ROBOTS

In recent years, robotics have become increasingly popular in manufacturing, healthcare, and other industries. They offer a range of benefits, including increased efficiency, improved quality, and reduced costs. In this blog post, we will explore one of the types of robots which has become a staple in the industry; read more about the uses of collaborative robots.

What are Collaborative Robots?

Collaborative robots, also known as cobots, are a type of robot that is designed to work alongside humans, often in a shared workspace. Unlike traditional industrial robots, which are typically large, heavy and caged off from human workers, cobots are designed to be lightweight, flexible and safe. They are equipped with sensors and other features that allow them to detect and respond to the presence of humans in their workspace, preventing collisions and other accidents. Cobots are also designed to be user-friendly, with features that make them more approachable and easier to use for non-experts. Cobots are a relatively recent innovation in the field of robotics, and they already have a significant impact on the manufacturing industry and beyond.

Advantages of Collaborative Robots

The following are a few advantages that collaborative robots bring to a workplace which can be utilized by your industry.

Collaboration

The main advantage of cobots is their ability to work alongside human workers. They can collaborate with human workers, performing tasks that require strength and precision, while leaving more complex tasks to the human workers. This creates a more flexible and efficient workplace, where human workers can focus on tasks that require creativity and problem-solving skills while leaving the more repetitive and physically demanding tasks to the cobots.

Safety features

Similar to the theme of collaboration, one of the other key features of cobots is their safety. Unlike traditional industrial robots, which are often fenced off to protect human workers, cobots are designed to work safely alongside humans. They are equipped with a range of sensors and other safety features, including collision detection and force limitation. This means that if a cobot comes into contact with a human worker, it will automatically stop or slow down to prevent injury. This is especially useful for small to medium businesses where employees could be in close proximity to it.

Versatility

Cobots are also highly versatile, with the ability to perform a wide range of tasks. They can be programmed to perform simple repetitive tasks, such as picking and placing items on an assembly line, or more complex tasks, such as welding and painting.

Flexibility

Another advantage of cobots is their flexibility. They can be quickly and easily reprogrammed to perform different tasks, making them ideal for small-batch manufacturing and other applications where production needs can change rapidly. This flexibility allows companies to respond quickly to changing market demands, reducing lead times and improving overall efficiency.

Ease of use

In addition, a key feature of cobots is their ease of use. They are designed to be user-friendly, with intuitive interfaces that allow non-experts to operate them with ease. This makes them ideal for small and medium-sized enterprises that may not have the resources to hire dedicated robotics experts. Cobots can be programmed using a range of methods, including hand-guiding, teach pendants, and graphical interfaces.

Affordability

Finally, cobots can be more affordable than traditional industrial robots, making them accessible to small and medium-sized enterprises that may not have the resources to invest in expensive automation equipment.

Conclusion

Collaborative robots are transforming the workplace, offering a range of benefits, including increased efficiency, improved quality, and reduced costs. They are safe, easy to use, versatile, and can collaborate with human workers to create a more efficient and flexible workplace. As the technology continues to evolve, we can expect to see more and more cobots in a range of industries. Thank you for tuning into our blog for this week, if you have any questions about collaborative robots, or inquiries about our collaborative robot cell products, please feel free to reach out: https://diy-robotics.com/contact/

THE BASICS ABOUT FANUC ROBOTS

In recent years, robotics has become an increasingly important and rapidly growing field. Robots are being used in a wide range of industries, from manufacturing and logistics to healthcare and entertainment. As the capabilities of robots continue to advance, they are poised to play an even larger role in our society in the coming years.

One of the leading contributors to the robotic industry is the Japanese company FANUC. This company is known for producing high-quality robotic systems that are used in a wide range of industries, from automotive manufacturing to food processing.

Fanuc robot M-20iS35

FANUC Robot Capabilities

FANUC robots are renowned for their precision, reliability, and versatility, and they are trusted by businesses around the world to improve efficiency, reduce costs, and increase productivity. They are designed to handle repetitive tasks with high accuracy and efficiency, freeing up human operators to focus on more complex and value-adding activities. These robots range from small compact models to large heavy-duty ones. They can be used for a variety of tasks, such as welding, material handling, painting, packaging, and more. FANUC robots can be integrated with other automation systems, such as CNC machines and sensors, to create a seamless and efficient production line.

One of the key features of FANUC robots is their advanced control system. The robots are equipped with FANUC’s proprietary R-30iB controller, which allows for precise and responsive motion control. The controller can also be programmed to perform complex tasks, such as path planning and collision avoidance.

FANUC robots are also designed with safety in mind. They come with a variety of safety features, such as collision detection and emergency stop buttons, to ensure that they operate safely around human workers. Comprehensive support is also available, including training, maintenance, and repair services. A range of software tools and accessories is present to help users optimize their robot’s performance and efficiency.

Programming FANUC Robots

CRX programmingFANUC robots are designed with ease of use in mind. The robots can be programmed using FANUC’s proprietary programming language, which is easy enough to learn and use. Instructions can be programmed using a computer or a teach pendant, which is a handheld device used to manually input commands to the robot. FANUC programming is flexible. Robots can be reprogrammed quickly and easily to adapt to changes in manufacturing processes or to perform new tasks. This allows for greater agility in manufacturing operations and can help businesses stay competitive in a rapidly changing market.

Fortunately, there are many resources available to help programmers learn FANUC programming. FANUC offers training programs and certifications for programmers, as well as online resources such as forums and tutorials. In addition, there are many third-party training programs and resources available that can help programmers develop their skills and knowledge.

The programming language used in FANUC robots is called KAREL, which stands for “Kawasaki Robot Language.” KAREL is a high-level language that is specifically designed for robotic applications. It is similar to other programming languages, such as C++ and Java, but with a syntax and structure that is optimized for robot control. Some of the basic programming concepts used in KAREL include variables, loops, conditional statements, and functions.

DIY Robotics & FANUC

working on cell about fanuc robotsAt DIY Robotics, we design and produce robotic work cells which are perfect to house and assist FANUC robots (as well as other robot brands) with their daily automated tasks while keeping the work environment safe and secure. Each of our various work cells can house different FANUC models and can be customized to match or accommodate your production floor layout and requirements. For more information about our robotic work cells or the FANUC robots they are equipped with, please feel free to visit our product page: https://diy-robotics.com/products/

Overall, FANUC robots are an excellent choice for manufacturers and industrial users looking to automate their production processes. With their precision, speed, and reliability, FANUC robots can help companies improve their productivity and reduce their costs, while also improving the safety and working conditions for their employees.

References

WHY YOU SHOULD INCLUDE COBOTS INTO YOUR COMPANY

Companies have already integrated robotics into their production floors in order to increase production, safety, and consistency. However, the majority of these robotic installations are of the industrial category and are often complex to program or install. The majority of this robot category provides a more permanent solution and are ideal for large business where layouts or production steps rarely change. Luckily, there is a category of robot which is excellent for industries looking for a more adaptable solution: the cobot.

What is a Cobot?

A cobot is a term used to represent a collaborative robot. These robots are specifically designed to be able to work alongside humans in a production setting. They have reduced speed, unique safety features, and can work in an open system, unlike their industrial robot counterparts. They often take the shape of a human arm and hand, and are great for repetitive and dangerous tasks; which makes them an excellent addition to any workspace.

Advantages of a Cobot

Like any robotic equipment, cobots are extremely accurate and efficient at performing their tasks. This will result in improved production rates, fewer errors or defects, increased overall efficiency, etc. Although slower, cobots have improved safety features and are usually cheaper than industrial robots.

cobotCobots are designed to be installed quickly. They usually come pre-assembled in a box or crate and only require a few anchoring bolts and power connections before the cobot can start functioning. With the right training, these types of robots can be installed and programmed internally. Some companies, including DIY Robotics, even offer user-friendly software and HMIs to help guide the acquiring company to an easier solution.

To build upon on the above points, cobots are also versatile and mobile. This means that a cobot can be programmed to perform a task one day, but then be moved to another with little to no hassle. In other words, one cobot has the capability to perform at multiple workstations. This is usually accomplished by coding multiple projects, and installing the cobot on a robotic cell with wheels. This makes them an excellent addition to small or medium business types that are looking to integrate robotic equipment for the first time.

Collaborative robots provide an excellent solution for any industry looking to automate a production setting. They are designed to work alongside humans and provide a more accurate and consistent job to everyday production. Due to their user-friendly interfaces, it allows a worker to program these robots with little experience in programming. The majority of cobots are also versatile to allow it to work on multiple projects at a time, or be relocated with ease. It is this combination of benefits which allows cobots to be a worthy option when planning to automate production tasks.

At DIY Robotics, we offer a range of collaborative robot work cells which will contribute greatly to your production tasks. They offer all the advantages stated above while providing additional functionality with the installed cell. If you would like more information regarding our collaborative robot products, feel free to visit our product page: https://diy-robotics.com/products/. If you have a question about this article or any of our products, please don’t hesitate to contact us: https://diy-robotics.com/contact/.

References

  • Matheson, E., Minto, R., Zampieri, E. G. G., Faccio, M., & Rosati, G. (2019, December 6). Human–robot collaboration in Manufacturing Applications: A Review. MDPI. Retrieved September 26, 2022, from https://www.mdpi.com/2218-6581/8/4/100/htm

COLLABORATIVE ROBOTS VS INDUSTRIAL ROBOTS

As technologies advance, manufacturing industries are looking for new and innovative ways to increase their factory production and efficiency. Robotic technology is widely used and is available for all production companies to achieve these goals. Many different kinds of robotic equipment are available to be integrated into a factory floor. They can be distinctly categorized into two groups: Industrial Robots and Collaborative Robots. Each of these options provides many benefits, however, based on the task or environment that they would be subjected to, one may prove to be a better fit over the other. 

Industrial Robots

Advantages

Industrial robots can be easily programmed or automated to perform repetitive tasks within a production workspace. This will allow employees to focus on or be reassigned to more meaningful tasks which aren’t as repetitive or dangerous. On a similar note, this also reduces any risks or hazards an employee would be subject to since industrial robots are replacing them and are often independent and require minimal human interaction.

Due to general robotic capabilities, integrating industrial robots will increase the overall efficiency of a workplace. It is well known that robots are faster, more accurate, and more consistent than human employees. Industrial robots perform their tasks away from human workers and therefore can operate at higher speeds than collaborative robots.

Compared to Collaborative Robots, Industrial Robots are more often designed for heavier tasks like the assembly of large products, welding, cutting, etc. This makes them ideal for factories like the automotive industry, where the parts are heavier and require unique or hazardous steps during production.

Limits

Since industrial robotics provide a more permanent solution to automated production, it is often a hassle to reassign them to other production tasks. They are commonly bolted to the ground and are programmed to focus on a specific task at the time of installation. In order to reprogram or relocate an industrial robot, a qualified employee would need to be on-site to accomplish the task properly.

As stated previously, industrial robots are meant to perform their tasks away from human workers. Their operation workspace can be dangerous due to the fast and heavy moving objects. Hence, integrating a safety cage or robotic work cell would be ideal to eliminate any hazards.

Collaborative Robots

Industrial vs CobotsAlso known as Cobots, this style of robot is designed to work along with, or close to other human workers. These robots work with lighter materials, have a limitation on their movement speed, and come equipped with safety sensors to ensure safe interaction with nearby humans. Cobots are capable of a range of tasks including but not limited to pick and place, packing, palettizing, welding, finishing, painting, etc.

Advantages

The main aspect of a collaborative robot is the ability to work closely with humans. This means that a cobot would be ideal for smaller workspaces, or for production floors where robotic equipment is limited, and human workers fill most of the tasks. Examples include robotic welding assistants, palletizing robots, etc.

Unlike industrial robots which can take days or weeks to integrate, program, or relocate, collaborative robots are simple in design and can be adapted to a production floor with ease. The movements of the cobot can be taught by moving the robot arm by hand or using the cobot’s user-friendly software. This means that the cobot can be programmed to perform a task one day, and then be easily moved and programmed to another. This is especially useful if a production role needs to be filled immediately, or if the robot is used to assist various stations.

Limits

A collaborative robot is designed to work alongside human workers; therefore, certain safety requirements must be set in place to avoid injury. The majority of collaborative robots have a speed limit requirement of 250mm/s while in the vicinity of human workers. Collaborative robots are fully capable of reaching higher speeds; however, they must be isolated from employees. Many industries achieve this by integrating a robotic work cell or adding safety scanners.

Since cobots are designed to be versatile with their applications, many are manufactured for non-strenuous tasks and are meant to handle small and medium-sized objects. Therefore, collaborative robots wouldn’t be ideal for heavy manufacturing environments.

The Right Balance

At DIY Robotics, we offer a range of robotic cell products that can be tailored to your specific needs. Our robotic cells bring all the benefits of a collaborative robot while making no compromise to its speed or functionality. Due to their mobile design, our robotic cells can be relocated and reprogramed to any workstation with ease. Our robotic cells are designed to be as simple to program as possible. This is due to the external teach pendant as well as built-in programs within the cell. This includes but is not limited to a DIY Robotics software package, scroll menus to select different programs based on the robot chosen, indicators to inform the user of any problems or steps that need to be performed, etc. Each of these are displayed on a screen outside the cell for easy analysis and manipulation of the cell’s state/environment. We also offer free support and tutorials for all our equipment and products. These benefits can save a great amount of time for an industry, which will in turn increase their revenue.

Summary

To summarize, Industrial and Collaborative robots are both capable of a range of manufacturing applications. Industrial robots provide a high-efficiency, heavy-duty way to accomplish production tasks. Collaborative robots provide a user-friendly, adaptable, and safe addition to a workspace. Depending on the tasks you need automated, one of these can provide the necessary solution. DIY Robotics offers a range of robotic products to satisfy your automation needs. For more information regarding our robotic equipment, or if you would like a product recommended, please feel free to visit our product page: https://diy-robotics.com/products/.

That concludes this week’s blog post on Collaborative and Industrial Robots. If you have any questions regarding the topics and information presented here, feel free to contact us and we will provide you with an expert on the topic: https://diy-robotics.com/contact/.

References

The Differences between FANUC LR MATE and FANUC CR ROBOT

Each year, around 1.6 million twins are born around the world. Some are identical and some are not. But even identical twins are not completely identical. The same could be stated regarding the FANUC CR robots and the LR Mate series robots. They may look like twins because they share similar physical designs with very little differences, but they are both quite different in many aspects. The major difference can be noted in their working speed, environment, and safety.

To better understand the FANUC LR MATE and CR Robots, we should review their capabilities, similarities and differences.

FANUC LR MATE SERIES

The LR Mate Series is a robot the size of a human arm and has a load bearing capacity of maximum 14kg weight across its range. It is compact and used for quick maneuvers and part processing in various industries ranging from food to automotive.

They can come with different options tailored to the work they do, altered according to the client’s requirements. We will now look at the specifications and major characteristics of the LR Mate Series:

  • Floor, Ceiling, Wall and angle mounting robots
  • Can work alongside other robots in close proximity due to its smaller work envelope
  • Sensors, camera, and other attachment options
  • Reaches up to 911mm
  • Internal cable routing
  • Short cycle times (speed up to 4000 mm/s)
  • Work envelope remains constant irrespective of mounting
  • 5 and 6 axis robots

The FANUC LR Mate Series is used for applications such as dispensing, pick and place, assembly, machine-tending, welding, painting, and many others depending on its field of application. Due to their high speed and accuracy, they increase the precision and throughput of the production. All these above-mentioned reasons have increased the popularity of the LR Mate Series among various industries. So far, they have shown remarkable usage growth in the metal and food industries as well.

FANUC CR ROBOTS

The name CR itself stands for Collaborative Robots. So, the FANUC CR is basically the LR Mate Series turned collaborative with some modified features. Therefore, the FANUC CR Robot is capable of safely working alongside humans in a production line. The highlight features of the CR Robots are as follow:

  • From 550 mm to 1813 mm in reach capacity
  • Maximum speed up to 1000 mm/s
  • Less floor space occupancy
  • Devoid of safety fences due to
  • Customizable settings for speed and safety
  • Compatible with a wide range of attachments like cameras, sensors, etc.
  • Highly reliable
  • Only comes in 6 axis variant for more control

The FANUC CR Series is equipped with a safe contact stop sensor technology which enables it to stop immediately when the robot is in contact with a person or an unidentified object. This makes it highly safe for humans to work around it without any safety fences. Moreover, for extra safety, we can manually regulate the speed and safety settings. The FANUC Teach Pendant gives access to a step by step process to set up CR robots for new and acquainted users.

FANUC CR Robots can safely handle tasks like palletizing, pick and place, applying sealants, painting, lifting/placing heavy components, assembling, quality checks, and machine-tending.

Now that we have seen the features of both the FANUC LR MATE and the FANUC CR robots let’s compare them to see the differences:

FANUC LR MATEFANUC CR ROBOT
Non-Collaborative robotsCollaborative robots
Come in 5 and 6 axes modelOnly come in 6 axes model
±0.01mm repeatability rate±0.03mm repeatability rate
Cannot work in close proximity with humansCan work alongside humans without causing any harm
Need safety fencesDo not require safety barriers
Light in weightHeavy in weight compared to LR Mate
Auto stop option not availableAuto stops when in contact with a person or any fixed object
Speed up to 4000 mm/sSpeed up to 1000 mm/s
Reach up to 911 mmReach up to 911 mm

These features and limitations of the FANUC LR MATE and the FANUC CR Robots make things really clear when manufacturers need to select the correct model according to their requirements. The wide range of products provided by FANUC thanks to its LR Mate and CR robots makes it easier to spend exactly on what is required and get customized accessories to cater to their needs. The new trend around collaborative robots tends to make them attractive, but their performances are less effective than traditional robots.

Therefore, before opting for a cobot, take the time to figure out if a collaborative application is really needed or if an industrial robot in one of our pre-secured robotic cells could do the job with a better output. Discover more about our Collaborative Robotic Cells and Modular Robotic Cells on our product pages.

Industrial Robotic Cell - DIY-Robotics

VISIT US

References

Why a machine-tending robot?

Sometimes it’s better to break down complex words to understand their meaning. Let’s do that with the word: Machine-Tending. The first part of the term is Machine. We probably all know what the definition of a machine is. As for the second part of the term, tending refers to the act of carefully providing for someone or something. So, those two words together and in the context of industrial automation, refer to the loading or unloading of parts or material on a machine.

Robotic Machine-tending:

Machine-tending is one of the most basic automation required by any job, shop, or manufacturing unit. Traditionally, operators feed in or remove the parts or material from machines. Though most of the industries are currently using humans as their machine-tending tools, that is changing. Thus, machine-tending robots will replace these operators and make them available to do more complex work.

robot machine tending

On top of basic loading/unloading of parts or raw materials, machine-tending robots are also capable of doing more complex work: picking up parts from a supply area and placing them on a designated machine, but also performing secondary applications, such as assembly, cutting, and inspection.

Applications:

With a wide array of parts that can be handled, ranging from a tiny pin to a large refrigeration system, there are various applications where machine-tending can be used:

Machine Tending Application
  • Loading products in a CNC, milling machine
  • Holding parts for welding operations
  • Grinding, stamping, and punching

Benefits:

Due to their wide range of applications and working capacities, machine-tending robots offer many benefits.

  • Can reduce strain and accidental injuries to operators due to repetitive, dangerous work
  • Increases production, quality, production rate, and consistency
  • Fast change over between products
  • Lower operation costs with a quick ROI
  • Customizable with various robot grippers, enabling it to work in continuously changing product ranges
  • Capability to work secondary operations
  • Increases system and manufacturing line uptime
  • Round the clock manufacturing capability as no fatigue can affect the production
  • Requires minimal maintenance and assistance
benefits

Choose Right, Choose Best:

To select the best machine-tending robot for a specific industry, certain things need to be taken into account. The selection process takes various factors into consideration :

  • Type of industry and machine on which the robot will be working
  • Investment budget
  • Shape, size, and weight of the parts to be handled
  • End effector grip tools requirement
  • Required speed for the task
  • Maximum payload of the robot
  • Vise, if needed
  • Multi-machine work capacity
  • ROI of the machine-tending robot
  • Robot limitations and work envelope

There are various companies on the market providing customizable machine-tending robots and robotic cells. Moreover, machine-tending robots help SMEs utilize their machines to their maximum capacity. It is very important to select the best suitable machine-tending robot to maximize profits. This helps SMEs gain an advantage over large-scale companies. So, by correctly choosing the machine-tending robot, companies can compete in this evolving market. It automates the industry with minimal investment and helps them maximizes their throughput.

If you have a hard time choosing the best machine-tending robot for your project, feel free to contact us.

Industrial Robotic Cell - DIY-Robotics

VISIT US

References