Manufacturers considering robotic automation for the first time may be tempted to ask, “How big of a robot should I buy?”
It’s a reasonable place to start but not the most important question.
Choosing a robot before understanding the application can lead to a knee-jerk solution that is oversized, undersized, unnecessarily complex, or just not suited to the way your operation works.
The better way to start is with these two questions:
Your goal should be to build an automated solution that makes sense for your product, process, people, and production goals.
That means looking beyond the robot itself. The robot is one part of a larger system designed around the job you need to accomplish. The complete system is the robotic work cell.
A robotic work cell is an automation station that combines a robot with the equipment and technology needed to perform a particular task.
That might mean a robot receiving parts from a conveyor, picking and placing components, inspecting a part, assembling products, or transferring finished parts to the next stage of production. The size and complexity of that cell can vary.
A smaller application may place delicate electrical components onto a circuit board or use a probe to measure the depth of a drilled hole. A larger application could involve handling automotive panels, moving heavier components, or palletizing finished products.
The robot is often just one component of a larger system, such as a production line with multiple machines, robots, conveyors, sensors, and controls working together in a coordinated process.
What combination of technologies will allow your process to run reliably, safely, and efficiently?
Depending on the application, a robotic work or assembly cell may include:
Related: Automation for Modern Manufacturing
Not every application needs every component. Some projects may be simple, but others may require several technologies working together.
Different manufacturing applications require different robotic solutions.
The application drives the specifications for the robot, including robot configuration, reach, payload, speed, accuracy, tooling, controls, and safety requirements. It helps to start with the “why.”
What is the business trying to improve?
Or all the above? Once those goals are clear, the conversation can move to what systems are needed to accomplish them. Here are some questions to consider at this stage:
Different processes require different robots.
What will the robot be handling? Will it be picking, moving, assembling, dispensing, inspecting, or welding? The product and process can have a major impact on robot selection. The size, weight, and shape of the product, as well as the speed or available working area of the application are just a few factors that can influence your decision.
There’s another consideration that manufacturers sometimes forget. It’s not just the item being moved that must be considered. End effectors, the tool attached to the end of a robotic arm, also contribute to the robot’s payload; they include devices like grippers, process tools like welders or paint sprayers, or sensors involved in the task.
Payload also affects how quickly and accurately the robot can move. A robot operating near its maximum payload may need to reduce speed to maintain control, placement performance (repeatability), and prevent premature failure or repair of the robot.
Size the robot for the complete application, not just the weight of the part.
The production environment can also influence the type of industrial robot you choose. Some applications are exposed to hazardous conditions, such as chemicals, heat, sparks, or contaminants, and may carry risks of fire, corrosion, or combustion.
Will the robot be exposed to chemicals? Heat? Dust or other contaminants?
Some environments, such as food processing or clean rooms, may require washdowns, so robotic components must be sealed to protect the robot from contamination or moisture-related damage.
Other processes may take advantage of the robot being mounted upside down or on a wall. This can allow for more clearance for other equipment in the process or better freedom of movement of the robot working within a defined space.
The conditions of the work environment can also affect the selection of tooling, controls, and other configurations needed for the task.
In many applications, the robot isn’t working alone. It may need to communicate with other systems like vision systems, PLCs, sensors, probes, conveyors, or other eqipment. That communication allows the automated system to share and respond to information about part location, measurements, machine status, and other conditions.
For example:
Most modern robots now have several communication methods available to address communication with different types of devices. These include most common fieldbuses (Ethernet/IP, Profinet, EtherCat, etc.), as well as discrete I/O. Many systems allow for using multiple methods. As an example, the robot can receive a discrete IO signal from a sensor while communicating position information through Ethernet / IP to a PLC.
A safety plan should be part of the discussion at the very beginning of a robotic automation project, before a robot is even purchased.
The plan should include a safety evaluation that assesses all potential hazards that can occur during installation, set up, programming, operation, or routine maintenance of any robots or machinery. When hazards cannot be engineered out through the design itself, physical safeguards, control systems, and emergency stops may be required.
The appropriate safety strategy will depend on the type of industrial robot, tooling, application, environment, and how people will interact with the system.
However, cobots still require safety measures. The tooling attached to a cobot can create serious hazards. Imagine a cobot with a cutting tool, laser, or a welding tool attached. If proper safety procedures are not in place, a simple malfunction or misstep by personnel could create significant risks for nearby workers.
Before finalizing a purchase, don’t forget to look at the following:
Considering these questions early can help you design the right solution from the start.
The idea of a fully automated production line can be overwhelming, especially to small to mid-size businesses new to robotics. A company may know that it wants to automate but may not have the budget or need for a large automated system.
A robotic work cell can be a manageable starting point. At MCE, we call it an 80% solution.
We work with manufacturers that want to get started with automation but may not need or be ready for a fully integrated robotic line. We help them decide on the right solution by evaluating their current process, identifying bottlenecks, and proposing robot cell solutions that meet their production goals. Depending on their application needs, the solution can include:
Once we find the right solution, the equipment can be appropriately sized, assembled, and delivered directly to your facility. The remaining 20% is the programming and product-specific wiring that can be completed by the customer, MCE, or a third-party installer.
This approach gives manufacturers another option besides doing everything themselves or committing to a full-scale automation project that is out of their budget.
We are certified dealers for top-rated robotic equipment manufacturers and for the following collaborative technologies:
As your production needs change, we’re there to help you modify an existing setup or configure a new application with vision systems, tooling changes, or larger robot options.
Talk to us today to learn more about successfully implementing a robotic work cell solution in your facility.