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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

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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!

For more information visit:

www.abb.com/robotics

Or contact:

[e-mail]

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