Robots in Process Industrial Engineering
Robots in Process Industrial Engineering
Objectives:
1. Application
of Robots in Manufacturing Operation Processes
2. Pros and Cons of Using Industrial Robots in Manufacturing Operation,
3.Case Study,
4. Sources.
Application
of Robots in Manufacturing Operation Processes
Today most
robots are used for manufacturing operations in Process Industrial Engineering;
the applications can be divided into three categories:
(1) Material
handling,
(2) Processing
Operations,
(3) Assembly
Operations,
(4) Inspection.
(1) Material-Handling applications include material transfer and machine loading and
unloading. Material-transfer applications require the robot to move materials
or work parts from one location to another. Many of these tasks are relatively
simple, requiring robots to pick up parts from one conveyor and place them on
another. Other transfer operations are more complex, such as placing parts onto
pallets in an arrangement that must be calculated by the robot. Machine loading
and unloading operations utilize a robot to load and unload parts at a
production machine. This requires the robot to be equipped with a gripper that
can grasp parts. Usually the gripper must be designed specifically for the
particular part geometry.
(2)
Processing Operations: In robotic processing
operations, the robot manipulates a tool to perform a process on the work part.
Examples of such applications include spot welding, continuous arc welding, and
spray painting. Spot welding of automobile bodies is one of the most common
applications of industrial robots in the United States. The robot positions a
spot welder against the automobile panels and frames to complete the assembly
of the basic car body. Arc welding is a continuous process in which the robot
moves the welding rod along the seam to be welded. Spray painting involves the
manipulation of a spray-painting gun over the surface of the object to be
coated. Other operations in this category include grinding, polishing, and
routing, in which a rotating spindle serves as the robot’s tool.
(3) Assembly: The use of robots in assembly is expected to increase because of
the high cost of manual labour common in these operations. Since robots are
programmable, one strategy in assembly work is to produce multiple product
styles in batches, reprogramming the robots between batches. An alternative
strategy is to produce a mixture of different product styles in the same
assembly cell, requiring each robot in the cell to identify the product style
as it arrives and then execute the appropriate task for that unit.
The design of
the product is an important aspect of robotic assembly. Assembly methods that
are satisfactory for humans are not necessarily suitable for robots. Using a
screw and nut as a fastening method, for example, is easily performed in manual
assembly, but the same operation is extremely difficult for a one-armed robot.
Designs in which the components are to be added from the same direction using
snap fits and other one-step fastening procedures enable the work to be
accomplished much more easily by automated and robotic assembly methods.
(4)
Inspection is another area of factory operations in
which the utilization of robots is growing. In a typical inspection job, the
robot positions a sensor with respect to the work part and determines whether
the part is consistent with the quality specifications.
In nearly all
industrial robotic applications, the robot provides a substitute for human
labour. There are certain characteristics of industrial jobs performed by
humans that identify the work as a potential application for robots:
(1) The
operation is repetitive, involving the same basic work motions every cycle;
(2) The operation is hazardous or uncomfortable for the human worker
(e.g., spray painting, spot welding,
arc welding, and certain machine loading and unloading tasks);
(3) The task requires a work part or tool that
is heavy and awkward to handle;
(4) The operation allows the robot to be used
on two or three shifts.
Pros and Cons of Using Industrial Robots
in Manufacturing Operation
Manufacturing
and Distribution
Today’s
industrial robots work in a wide range of industries, from semiconductors and
automobiles to plastics processing and metal forging. Pretty much any
repetitive operation is a great job for a robot, particularly if it’s dangerous
or difficult for people.
Robots have been
used for high-volume operations, but as the technology advances and costs
declines, more options and opportunities are opening for medium- and
small-sized operations.
At the same
time, these robots are helping manufacturers address many of the key challenges
they face, including tight labor pools, global market competitiveness and
safety.
If you're
curious whether robots can enhance your value stream, here are the main pros
and cons to consider:
Advantages of
industrial robots:
·
Better Quality and Consistency: Along with other tech — such as the industrial internet of things
(IIoT) or 3D printing robots — industrial robots are able to provide better
production quality and more precise and reliable processes. Added benefits also
include reduced cycle times and real-time monitoring to improve preventive
maintenance practices.
·
Maximum Productivity and Throughput: An industrial robot increases speed for manufacturing processes, in
part by operating 24/7. Robots don’t need breaks or shift changes, for example.
The speed and dependability of robots ultimately reduces cycle time and
maximizes throughput.
·
Greater Safety: Using robots for repetitive tasks means fewer risks of injury for
workers, especially when manufacturing has to take place under hostile
conditions. In addition, supervisors can oversee the process online or from a
remote location.
·
Reduced Direct Labor Costs: The cost of having a person handle many manufacturing operations is
often more expensive than robot. This can also free up workers so their skills
and expertise can be used in other business areas such as engineering,
programming and maintenance.
·
Keeping Manufacturing Localise: Some argue that robots are taking jobs away from U.S. workers, but
that's not necessarily the case. Industrial robots there are typically
integrated into a series of operations that require human expertise. For
example, you could have a robot welding parts that are handed off to a person
to perform a task that requires a human's intuitive "if, then"
thinking.
Disadvantages
of industrial robots:
1.
High Initial Investment: Robots typically require a large upfront investment. As you
research your business case for purchasing, you need to consider all the costs,
including installation and configuration. You should also evaluate whether your
robot can be easily modified if you need to alter operation in the future.
2.
Expertise Can be Scarce: Industrial robots need sophisticated operation, maintenance and
programming. While the number of people with these skills are growing, it's
currently limited. As a result, it's important to consider the personnel
investment you'll need to make to bring in that expertise or “retool” your
existing staff to take on the task.
3.
Ongoing Costs: While industrial robots may reduce some manufacturing labor costs,
they do come with their own ongoing expenses, such as maintenance. In addition,
you’ll want to consider the costs to keep your robot and any related IIoT
connected devices protected from cyberthreats.
Case Study:
Automating End-of-Line Processes in a Traditional German Brewery
Westheimer
Brewery, founded in 1862, is a private brewery rooted in more than 150 years of
tradition. From their factory in the Sauerland region of Germany, they produce
regional beer specialties and prepare them for distribution both regionally and
internationally. In order to remain competitive in an increasingly diversified
market, Westheimer Brewery installed a Kawasaki robot in August 2017, one of
the first to do so among their competitors. The ease, flexibility and
efficiency of their automated system has inspired them to automate additional
processes in the future.
Challenges
·
Qualified workers increasingly
difficult to find
·
Current tasks ergonomically
challenging for employees
·
Antiquated existing machinery
prone to breakdowns
·
Flexibility a must for evolving
product line
Finding
qualified workers is a growing challenge for Westheimer Brewery and the greater
manufacturing industry. The number of applicants in the region is continuously
declining, which can cause lapses in production. In addition, Westheimer wanted
to reduce the physical strain on employees that can be caused by end-of-line
work.
The brewery’s
previous, older palletizing machinery would frequently break down, making it
clear that it was time for modernization.
"The modernization and automation of the plant must begin here. In
the long term, the entire infrastructure of the bottling plant will be renewed
and optimized,” said Master Brewer Jörg Tolzmann.
The production
volume of the Westheimer Brewery has remained at a constant level for years,
but the increasing product diversification was another factor the company had
to consider when building their new system. It had to be flexible and adaptable
to new products.
Solution
Kawasaki
CP500L robot and Cubic-S safety
hardware/software installed.
Robot loads
empty bottles onto pallet en-route to filling station and filled bottles onto a
pallet for distribution.
Tool changing
station allows system to adapt to product changes.
Empty bottles
are manually fed into an automatic sorting machine at the entrance of the
plant, where they are cleaned and rinsed. After filling, the bottles are
inspected and placed in crates. These
steps are still manual, but Westheimer plans to install a pick and place robot
in the future to handle these tasks.
From there,
production takes place on two interconnected levels – empty bottles and the
final product are processed on the lower level, and bottles are filled on the
upper level. In the new system, a conveyor belt transports the bottles between
the two levels, which allows crates to be loaded and unloaded by the Kawasaki
CP500L palletizing robot.
The robot sits
on a concrete base with cabling laid through its interior. The brewery worked
with German Kawasaki integrator Schröder Engineering Team to design the ideal
system for their process. Together with Kawasaki Robotics GmbH, the integrator
was involved in every step of the installation.
Flexibility
achieved
The new
palletizing system is flexible and adaptable to new or different products. A
tool changing station is connected to the magazine, where the right gripping
tools are readily available for the robot to change based on product type. This
flexibility not only saves time, but also enables significantly higher and
consistent product quality.
The high degree
of flexibility is also a great advantage when it comes to external orders.
Westheimer Brewery works in a one-shift operation, and special orders - such as
organic beer - are added at regular intervals. They also support other
breweries from their large network and numerous craft beer labels and start-ups
that have shaped the beer market in recent years. Having a flexible automated
system allows Westheimer to keep up with beer industry trends more easily.
"In the
1970s, 1980s and 1990s the question in breweries was simple: barrel or bottle?”
Tolzmann said. “Today, we change production four times a day on average -
precise planning and flexibility are essential."
High
performance robot & safety software
To meet their
goals, the brewery needed a workhorse with a high payload that could fit in
their space. The Kawasaki CP500L robot checked all of the boxes: the compact
palletizing robot has a payload of 500 kg and a maximum speed of 900 cycles per
hour. With a reach of 3,255 mm, a palletizing height of 2,200 mm and a net
weight of only 1,650 kg, it is the most powerful robot in its class.
In addition to
the speed, precision and compact design of the robot, the independent
loading of the machine and Kawasaki’s Cubic-S safety system were also key
selling points. A new chain gripper for the same purpose would have required
more programming and been more susceptible to faults.
After a few
weeks of fine-tuning and a comprehensive safety check, the plant went
into operation in August 2017. When the installation was completed, Tolzmann
was pleasantly surprised with the seamless transition. "I know from other
companies that comparable plants were not ready to start even after eight
months,” Tolzmann said. “Here, everything was ready in less than two months. We
were also able to remain within our budget without any problems.”
Results
1.
Robot palletizes at a rate of
1,200 crates per hour, with potential to go 25% faster
2.
Employees redeployed to more
suitable roles
3.
Brewery plans to introduce more
robots for other processes
Currently, the
Kawasaki robot CP500L processes more than 1,200 crates per hour - and there is
even more potential, says Tolzmann. "For optimum coordination with our
older machines, we are not yet able to cope with the speed of the robot. After
the modernization of our conveyor system, the robot will be up to 25%
faster."
Thanks to its
integrated control system, the robot enables effective crate handling utilizing
a single machine in a small space. The Cubic-S-based safety system also
functions reliably and easily: As soon as the door to the robotic cell is opened,
the power is switched off and employees can enter the system without
hesitation. A one-week training course at Kawasaki Robotics taught Tolzmann and
integrator Thomas Juckenath everything they needed to know to operate the
robot.
The brewery’s
robotic palletizing system simultaneously helps them combat an industry-wide
labor shortage while allowing them to redeploy their existing employees to more
human-friendly roles better suited for their skills.
Blazing a
trail
From Tolzmann's
experience, the automation of the brewery market is still at an early stage -
despite some pioneers. Although trade fairs show a clear trend towards robots,
equipment such as light barriers, pneumatic motors and mechanical solutions are
really the closest most breweries get to automation. In addition, many of
Westheimer Brewery's suppliers do not yet rely on robot-based automation. “The
companies know their old machines and the necessary maintenance,” Tolzmann
said. “But we know from our own experience that thinking outside the box
quickly pays off.”
Sources:
1.
https://www.manufacturingtomorrow.com/article/2016/07/robots-in-manufacturing-applications/8333
2.
http://www.brainkart.com/article/Industrial-Robot-Applications_6413/
Industrial connectivity...
ReplyDeleteWell articulated, Even robots can't save you from getting C
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