Entries Tagged 'General Robotics' ↓

I recently sat down with Dwayne Smith, one of KC Robotics’ robotic engineers and a specialist is automated welding. I wanted to pick Dwayne’s brain about the benefits of robotic welding. Dwayne wanted to get back to work. “You don’t really want me to write something!” I assured him that I would do the writing. He humored me with answers to my obviously uninformed questions, but made it clear that he would rather be “back at the robot”.

This is what I got out of the conversation:

• Most of the welding applications set up by KC Robotics are MIG Welding.
• MIG stands for “Metal inert gas” (What does that mean?)
• In “MIG”, the weld is put down with a spool of solid-steel wire that is fed through the torch
• MIG is Dwayne’s preferred type of automated welding because it’s easier to automate with wire than it is with a stick and the “end of tip to torch is always consistent”.
• The key to quality automated welding is a good fixture and consistent input parts
• The benefits of automated welding are consistent welds, workplace economy, low overhead, and shorter cycle times. This means, in Dwayne’s words, “the end product is consistent, the robot saves bucks in labor costs, robots don’t complain, smoke cigarettes or file workers comp claims, and the factory is able to produce more product in a shorter period of time.”

I asked Dwayne why he likes welding jobs. He replied, “I don’t. Material handling is much easier.” So… why do you specialize is welding? I asked. In his typical economy of words, Dwayne answered, “I have a background in welding. It’s what I do.” With that, he excused himself so he could get back to work. “Marty (our customer) is probably looking for me,” he explained.

Before leaving the office, Dwayne plopped a book on my desk, saying, “I think the book can answer your questions better than me.”

Thanks, Dwayne. That’s what I wanted to do with my afternoon – read a welding textbook.

KC Robotics and Robotic Welding

KC Robotics specializes in system integration using new and used robots, individually designed end-of-arm tooling, project design and engineering, installation, and employee training. System Integration with robotic welding applications can be the most difficult of all applications. It requires more than one piece of equipment, including a robot, end-of-arm torch, wire feeder, welding gas, and a power supply. Because of the complexity of an automated welding system, it is important to partnership with a good integrator. The engineers and robotic programmers at KC Robotics can guide you and your employees through every aspect of setting up a robotic welding system. Contact KC Robotics for more information or a proposal. 513-860-4441 or info@kcrobotics.com

Most Popular Welding Robots sold at KC Robotics:

The most popular welding robots sold at KC Robotics are the ARCMATE 100 and 120 series and the FANUC S420if. The ARCMATE robots are perfect for manipulating the torch around small components. They are relatively small robots, fitting into tight manufacturing facilities. The ARCMATES are also fast robots which can increase the cycle time. The FANUC S420if has a longer reach, making it ideal for situations with large components.

Benefits of Robotic Welding Applications

The benefits of a robotic welding system completely outweigh the complexity of the set-up. Once the system is set up, the process requires little maintenance compared to manual welding. The benefits include:

• Quick return on investment
• Consistent welds
• Better Quality Control
• Less down time
• Increased cycle time
• Reduction in employee management expenses (insurance, workers comp, down time,etc.)
• Better working conditions for employees

MIG Advantages

• 1. High productivity, because you don’t have to stop to change rods.
• 2. Makes great-looking welds.
• 3. Little cleanup.
• 4. Can weld on stainless, mild steel, and aluminum.
• 5. Can weld in all positions.

MIG Disadvantages

• 1. Does not weld on paint, rust, or dirty surfaces.
• 2. Not good for thick steel, because it doesn’t get the proper penetration.

Popularity: 12% [?]

August 21st, 2008
ATI Industrial Automation’s 2nd Annual Open House and Training Seminar
Detroit, Michigan

ATI Industrial Automation, a world-leading engineering-based developer of robotic peripheral equipment will host their 2nd Annual Open House and Training Seminar at the Detroit, Michigan Sales Office. ATI will discuss in detail the many new end-effector products developed over the past year.

September, 2008
Conference for Vision Guided Robotics
September 30, 2008 - October 2, 2008
Novi, Michigan

The International Conference for Vision Guided Robotics brings together global leaders in this rapidly advancing area. Vision guided robots enable a host of new applications in just about every industry. Among the specific topics to be addressed will be:

•    Comparing vision guided robots to traditional pick and place operations
•    2D vision guidance techniques
•    Integrating 3D vision sensors with robots for flexible applications
•    The latest advances in object tracking and visual servoing
•    Case studies of successful applications of vision guided robots
•    How vision guidance can assist in traceability and error proofing

October, 2008
20th Annual National Robot Safety Conference
October 06 - 09, 2008
Indianapolis, IN

RIA holds its annual National Robot Safety Conference, helping attendees understand and comply with the robot and machine safety standards to keep their workplace safe and productive. Presentations include robot safety, standards, successful robot applications, the latest developments, and information important to everyone associated with industrial safety.

November 2008
16th Annual Robotics Industry Forum
November 5 - 7, 2008
Orlando, Florida

The 16th Annual Robotics Industry Forum brings together top executives from robot manufacturing companies, component suppliers, system integrators, end users, research groups, and consulting firms. This year, for the first time, executives from the Motion Control Association will also participate, as they launch their first MCA Business Conference. MCA is a sister trade group to RIA. Full details about the MCA event will be posted soon at www.motioncontrolonline.org

Popularity: 19% [?]

Referenced from The Top 10 Robotics Application Mistakes by Milton Coleman, Manager of Product Marketing/Technical Support – Linear Motion and Assembly Technologies, Bosch Rexroth Corporation, Charlotte, North Carolina

This article is a “must-read” for anyone setting up a robot cell. These the top ten mistakes. Check out the article for more information on each one.

Mistake 1: Underestimating Payload and Inertia Requirements
Mistake 2: Trying to Do too Much With the Robot
Mistake 3: Under Estimating Cable Management Issues
Mistake 4: LOSTPED or Failure to Consider All Application Elements Before Choosing a Robotics System
Mistake 5: Misunderstanding Accuracy Vs. Repeatability
Mistake 6: Choosing a Robotics System Based Solely on the Control System
Mistake 7: Failure to Accept Robotics Technology
Mistake 8: Overlooking the Need for Crucial Robot Options or Peripheral Devices
Mistake 9: Under- or Overestimating the Capabilities of a Robot Controller
Mistake 10: Failure to Consider Using Robotics Technology

More Robotics Application Mistakes:

•    Failure to Consider Future Applications for the Robot
•    Choosing a Robot Solely On Price
•    Not Understanding the Full Capabilities of the Robot before Implementation
• Not Fully Utilizing the Robots Capabilities
•    Believing Robotics Are Too Complicated
•    Believing There Is a Perfect Robotics System

Popularity: 30% [?]

Originally posted 08/13/2007, at Robotics Online

Automotive Orders Rise 76%, Fueling Growth

Ann Arbor, Michigan – New orders received by North American based robotics companies rose 39% in the first half of 2007, according to new statistics from the Robotic Industries Association (RIA), the industry’s trade group.

A total of 9,208 robots valued at $525.2 million were ordered by North American manufacturing companies through June. When orders to companies outside North America are included, total sales for North American based robot suppliers totaled 9,992 robots valued at $563.2 million. These totals represent a gain of 40% in units and 12% in revenue.

The April to June quarter was very strong, with increases of 60% in units and 24% in revenue over the comparable period in 2006.

The 2007 gains can be traced primarily to a 76% jump in orders to automotive manufacturers and their suppliers. ‘‘Automotive industry buying patterns for robots are quite cyclical and this year we’re seeing the upswing,’‘ said Jeffrey A. Burnstein, Executive Vice President of RIA.

For the complete article or more information about RIA and the robotics industry, visit www.roboticsonline.com or contact RIA Headquarters at 734-994-6088.

Founded in 1974, RIA represents more than 250 North American companies including leading robot manufacturers, component suppliers, system integrators, end user, research groups, and consulting firms. RIA’s quarterly statistics are based on data supplier by member companies and represent an estimated 90% of the North American market.

Popularity: 50% [?]

The problem faced by our customer was all about weight. Salt is heavy; salt bags weigh 50 pounds. Without a palletizing robot, an employee had to lift 50-pound bags all day and stack them on a pallet. By the end of the day, production slowed; throughout the year, employee injuries resulted in down time and higher costs.

Using a Fanuc S-420iF/RJ2 Robot, KC Robotics designed a system consisting of four conveyors and a specialized gripper to lift the bags. To begin the process, employees bag and seal crushed salt on the first conveyor. Bags of salt continue on a route to the second conveyor to be re-oriented for a vibrating conveyor. The vibrating conveyor vibrates the salt in the bags until the bags lay flat. The flattened bags transfer to a locating conveyor where the robot picks up the bags with a custom-made gripper. The gripper palletizes the bags on a skid in seven layers. A forklift operator moves the skid and replaces it with a new skid. The process begins again. Review out Palletizing Robot video to see the whole process:

Palletizing Robot Moving Salt Bags

This customer benefits from robotics in several ways:

1. The process is smoother and faster than a manual operation.
2. The robot eliminated a difficult to fill employee position by doing the heavy lifting.
3. Employee health problems and injuries associated with heavy lifting are eliminated.
4. The vibrator packs the bags flatter, allowing more bags per pallet.

The customer should expect this palletizing robot system to pay for itself in less than eighteen months.

Popularity: 67% [?]

In every successful manufacturing or distributing company there comes a time when production needs exceed current employment and output capabilities. For a small or medium sized company, the decision to expand now includes a variable not thought of even ten years ago: ROBOTICS. Expansion leaves managers with two choices: add employees or automate the system. In today’s marketplace, industrial robots are now affordable to the first time buyer, offering advantages in reliability and cost justification only available to large manufacturers a decade ago.

Buying your first robot is more affordable than ever. The first decision is whether to purchase a new or used robot. The number of reliable used robots available makes owning a pre-owned robot a widely accepted concept for both small and medium sized companies. The savings associated with pre-owned robots allows the buyer to spend more of their resources on integration and tooling. These two components of robotics are what make the system work.

Finding a reliable dealer/integrator is the single most important decision a new buyer must make. If you choose wisely, this company will support your automation throughout the installation, maintenance, and service life of your robot. Choose a reputable company with knowledgeable service technicians, customer-oriented management, and qualified references.

There are many things to consider when choosing a robot for your application. Features like payload, reach, repeatability, and work envelope all affect the success of your automation project. Choosing and engineering the end of arm tooling is critical in making the system work. A reliable dealer will work with you through each of these options, helping you to make an educated decision.

Finally, investigate the safety issues of robotics. It is important to install the robot according to safety standards established by OSHA. A well-planned robotic cell will increase the overall safety of your operation by eliminating human errors that cause industrial accidents.

By Bobby Griffin & Connie Carrier

Popularity: 43% [?]