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Robot Automation in
Manufacturing Industries
Improving….
- Productivity
- Process Quality
- Workplace Safety
Ove Leichsenring
ABB Robotics
Sweden
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Robot Automation in
Manufacturing Industries
Improving….
- Productivity
- Process Quality
- Workplace Safety
Ove Leichsenring
ABB Robotics
Sweden
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The word Robot?
Karel Capek’s play
“Rossum’s Universal Robots
from 1920
Robota - Czech, Slovak and
Polish noun for “work”
derived from “slave” or “servant”
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The world’s first robot?
Leonardo da Vinci’s robot
design from 1495
A knight in German-
Italian medieval armour
•
Sitting up
• Moving its arms
• Moving its neck
• Moving its jaw
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The world’s first robot?
17th century
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The world’s first robot?
Digesting Duck
created by Jacques de
Vaucanson in 1739
was able to eat grains, flap
it wings and excrete
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The world’s first robot?
The human machine
Barbarossa with his
creator 1900
Automaton =
self-operating machine
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What is a industrial robot?
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Classification of industrial robots by mechanical structure
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Classification of robots by mechanical structure
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Manipulator Parts: Articulated Robot
Motors axes 3-6
Motor axis 1
Motor axis 2
Gear box axis 2
Gear box axis 1
Base
Air and customer signals
Lower arm
Upper arm
Gear box axis 4
Wrist, axis 5 and 6
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The top 10 reasons for robot investment
Based on research carried out by the International Federation of Robotics (IFR)
Increase production output rates
Reduce operating costs
Improve process quality
Improve workplace health & safety
Increase product manufacturing flexibility
Reduce material waste and increase yield
Reduce labour turnover and difficulty of recruiting workers
Save space in high value manufacturing areas
Reduce capital costs (inventory, work in progress)
Improve quality of work for employees
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Robot Automation Examples
- Plastic fabrication
- Foundries
- Metal fabrication
- Food & Beverages
- Other Industries
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Injection molding, Assembly, Testing, Palletizing
Robotautomation in the Plastic Industry
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Examples of Robots in Plastics
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Robots in Plastic! Laser Robot
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Robot Applications in Foundry
Upstream Process
Sand Casting
Die-Casting
- High Pressure
- Low Pressure
- Gravity
Precision Casting
- Lost Foam
- Investment Casting
Forging
Downstream Process
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Brake press tending, Arc welding, Painting , Palletizing
Robot Automation in Metal fabrication
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Robot Automation in the Food & Beverage Industry
Picking
Packing
Palletizing/
Order picking
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Examples of Robots in Picking
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Important technology trends …..
?!
I can play soccer
and chess!
What can you do?
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Trend 1
- New Safety Concepts/Solutions
New concepts for man – mashine interaction
Safety via protocol and computers
Integration of standard safety busses
SafeMove
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Electronic Position Switches
No mechanical switches
Tomorrow
Position swiches, axis 1
Position switches, axis 3
Today
Position switches, axis 2
Technology Development for New Safety Concepts
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SafeMove
Collaborative operation with humans
Safe stand-still in Automatic mode with servos
engaged
Reduced cycle time
Reduced wear
Less safety equipment needed
Cartesian safe inclusion / exclusion
zones
Denser cell layout saves floor space
Simpler setup
More flexible than mechanical stops
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Trend 2
- Integrate control of process and additional equipments
Integrated process control including sensor, process quality
supervision etc.
Process machine
Integration of programmable process control engine (PLC)
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Example Paint Robot >Process Machine
Paint & Air Hose
Routing
Arrangements
Vertical Arm:
- Pressure Regulators
- Flow Sensors
- Flow Regulators
-Air Boosters
- HV Cascade
Horizontal Arm:
- Paint Dosing Pumps
- Color Changers
- Paint Mixers
- Pilot Valves
- Solvent Distribution
- Solvent/Air Mixer
Wrist:
-Gun Adapters
- Spray Gun
- Bell Adapters
- A/B Color Changers
- Needle Sensors
Inside Vertical Arm:
- Process Control Electronics
-Process Control Software
- Ex Barriers
Inside Horizontal Arm:
- Process Sensor Interface
-Paint Dosing Pump Motors
- Magnetic Valves
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Trend 3
- Extensive sensor support (Vision, Force, …)
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Force Control Technology for Material Removal
Adapt to variations
in the work piece
Fixed material
removal rate
Polishing
Pre-machining
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Trend 4
Products for the toughest environmental
demands!!
Foundry Plus
Foundry Prime
Wash Down
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Trend 5
- Controlling more equipments e.g. Multiple
robot arms
Easy Integration of external manipulators
Scaleable resources e.g. computer performance and memory
Integrated PLC engine
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Trend 6 - Easy to use
Interact from any device selected by the user
E.g. phone, PDA, PC, …)
Task level programming (what to do not how)
Maintenance free, Remote diagnostics, Predictive maintenance
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Trend 6 – Everything goes Virtual
Visualization during system
design
A common understanding leads
to a more optimized system
Validation of tooling and
fixtures before build
Avoid spending time and
money for rework
Robot programs written and
tested before commissioning
Get to production start earlier
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Virtual Robot Technology
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Look for the new automation possibilities!
Or contact:
siim.savila@ee.abb.com
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