subject: Evaluate For Industrial Automation [print this page] When there is an industry that is moving from the research and development phase of its life into a high production phase, there is a mandate to minimize the cost of manufacturing. Achieving the goal of cutting costs will give the business a better chance of creating a profit for the owners. While economical production is a main goal of the manufacturing unit, there is also a goal in manufacturing to attain a high level of performance from production. Often there are labor intensive operations that perform repetitive tasks in the production unit that increase direct and indirect costs.
With pressure to have high performance from repetitive production, while keeping costs as low as possible, a business becomes a practical candidate for automating tasks with robotics. Some industries have realized a 75% reduction in the direct and indirect labor costs when robotics have been introduced to the repetitive manufacturing process. The driving forces that have increased the implementation of industrial automation systems include falling prices of automation equipment, the continuously increase in labor costs, and huge strides in the capabilities of technology. Suggestions for the application of industrial automation products are many. Agricultural applications in commercial farming include harvesters that can do the slow monotonous process of collecting crops, while personnel are attending other tasks. Industrial automation in the automobile plants worldwide have been cutting and forming fabricated parts, assembling machinery, and inspecting parts for a very long time. Other areas in which automation services have become productive are the loading of bricks, monitoring radiation, measuring fluids and solids, die casting, heat treating metals, sand blasting surfaces, changing tools in machines, cleaning parts and other areas, and do quality control.
How can true payback be attained from operations that are done by industrial automation applications? There is that ever present initial cost of design and implementation of industrial automation robotics. This payback can be achieved most of the time when the process that is being automated is very complex or the value of the result of the process has a very high value. When the value of the end result of the process is very low, then the labor cost that is added to that will make the cost of the end product unacceptable. This is a time when an industrial automation definition becomes necessary. In some cases the end result of the process is not very high in value, but the time that takes for humans to perform the task is too slow for the required throughput. In this case, an industrial automation solution is necessary. This would also be the case when humans would make too many errors for the process to be economically done.
In the food industry industrial robotics are used for packaging, handling bags, stacking and assembling food parts. These are especially helpful in minimizing contamination when raw ingredients have to be repeatedly handled. Operation cost are minimized when industrial robotics are used to stack several different products on a single pallet. Of course this is done at the request of the customer. Meat and poultry is sliced into appropriate sizes in processing plants by industrial robots.
When a business is involved in the discovery of determining if robotics can help in the reduction of costs and the improvement of quality in its operation, there is a set of evaluation characteristics that are helpful in guiding the way to the proper implementation of robotics.
Payload - What is the maximum weight payload required when task is performed?
Motion - What are the motions that occur while the task is being done?
Cycle time - How much time is needed to effectively perform the task?
Position - What are the positions that are required to complete this task?
Operating environment - What is the operating environment for this task?
Each of these characteristics must be defined in detail in order to implement an effective robotic solution that will perform the task efficiently. Each type of robot that is available has its own strengths and weaknesses. In the evaluation process it is best to try to employ that robotic solution that will best fit the characteristics of the task and return the most efficient tool for the job at the least cost.
The four main types of robotic solutions that are available are Cartesian, SCARA, articulating, and delta or parallel. These are the ones that are used in manufacturing robotics.
Cartesian robots can be configured in two dimensional or three dimensional planes. These have a great deal of flexibility. Precise work can be done in a very large or very small area. There can be a great variation in the lengths of stokes that the robot is required to perform. Some models have the capability to repeat the same positions very accurately. Others models work at high speed with excellent positioning. The Cartesian robot can handle very high payloads. Typical applications for this robot are material handling, dispensing, or sorting.
SCARA (Selective Compliance Assembly Robot Arm) work in a cylindrical area and are capable of repetitive tasks with a small payload. Application examples are pick and place, packaging, material handling, and dispensing.
Articulated robots perform work in a spherical area. There is a great variation in the size and range of motion of these robot types. Articulating robots have a large degree of flexibility, performing multiple tasks in the work area. Application examples are welding, dispensing, assembly, and material handling.
Delta (Parallel) robotics also have a cylindrical work space. These have the ability to work at very high speed in an open work space. These robots save a great deal of space by being mounted over the work area.
