Flexible Automation

June 2022

Flexible Automation – Robotics, Servos, Rotary, Linear or What’s Next?

Automation is increasingly becoming a consideration for many companies in today’s fast-moving manufacturing environments. The need for flexible manufacturing cells to accommodate varying batch sizes, from small-batch manufacturing to mass-produced batch manufacturing, different processes, or indeed different products, is becoming the norm in production environments. Not only has this caused a shift in how machines are designed, but it also has an impact on inventory management, and supply chains have to be closely managed. Manufacturing and assembly machines are only one part, and therefore, warehouse automation has to be considered to ensure stock levels are optimised.

More and more small to medium businesses are adopting automation to help overcome labour shortages and become flexible in their offering and even total customisation of products. More recent developments, such as collaborative robots, are giving companies an option to embrace automation, which would normally not be affordable, by using simple-to-program cobot arms, allowing them to improve productivity and also upskill personnel, taking them away from mundane jobs. Automation is not about removing jobs, it is there to improve the quality of the products, and utilise workers in more value-added and rewarding tasks, which in many cases involves upskilling which in turn provides higher salaries and more satisfied employees.

Automation – “The way we have always done it.”

This is a term that is probably one of the most disliked in any innovative manufacturing company as it essentially means systems are not being updated, and processes are falling behind with new offerings not being made. The term “Smart Factory” has become a very hot topic and is commonly heard in descriptions along with “The Factory of the Future” and “Industry 4.0.” But what does this mean?

A smart factory with smart manufacturing is one that uses a lot of digital technologies and connected devices to link production systems and machines. Creating data that can be used and acted upon is the ultimate goal in order to make decisions. Artificial intelligence is also becoming the norm in new processes, with machines now learning as they go and providing valuable data through automatic machine learning.

Examples of Automated Systems

Manufacturing processes have traditionally been based on linear systems or rotary systems; although a certain degree of flexibility can be added to allow for a change in parts or products, a small number of items are not suitable for small batches, quick changeovers, or complete customisation are common.

Thinking Out the Box for Flexible Automation

To allow for flexibility, intelligent mover systems have to be considered. The ability to move between different positions in different sequences is a must-have, and this can only be achieved by using up-to-date automation technology.

If we consider modern warehouse systems, such as those supplied by https://www.elementlogic.co.uk/, their proven software – eManager – enables AutoStore to communicate with clients ERP (Enterprise Resource Planning) or Warehouse Management System (WMS) to optimise workflow and maximise the efficiency of warehouse processes. Utilising a type of cart robot, these fast-moving multidirectional workhorses seamlessly communicate with each other to retrieve items that have been requested to allow them to be delivered at defined points. This approach makes customisation for the end user much easier and faster than traditional warehouse storage systems, which can be seen within case studies of AutoStore solutions implemented by Element Logic in a number of different industries.

So, is this Larger-Scale Approach Possible?

Robots, or interconnecting servo drives that can be programmed to move to randomly selected positions if desired, much like a vending machine, are often used to move to different locations, which can be frustrating, or worse if larger areas are required.

For the factory of the future, fast-moving and flexible approaches are required, and the technology required is here today. As an example, Beckhoff is a leading automation company and uses proven PC-based control technology. One of their latest products, the X PLANAR, gives the unique advantage of efficient production with batch sizes of 1 being possible for all industries. Using magnetic levitation, which can replicate traditional transport technologies, the movers can move to an almost unlimited number of positions and even between machines, which mitigates the limitation of the area covered.

Beckhoff XTS

Similar to automated guided vehicles (agvs), the user benefits from the freedom of movement of the object carriers: Individual goods can be transported to any location via any route.

Whilst combining this flexibility with the dynamics of conventional linear motors offers added value through cycle-time-optimisation, by the linking of individual production steps. In addition, the XPLANAR significantly simplifies individual production steps because the degrees of freedom and accuracy normally only associated with robotics can be used for 6D product handling.

The concept of product positioning during processing is applied to the transport system, and by a link to an ERP system, it can provide a very flexible, automated and fast transport system. From a running point of view, the floating movers remove the need for mechanical guides and, therefore, drastically reduce cleaning and maintenance.

Deployed based on the required transport weights and product distances, movers are tracked as they transport each product through the machine along individually defined routes, and this approach makes rigid station sequences a thing of the past. The movements of the individual movers are completely decoupled from each other: The products may overtake each other, and they can be discharged or be buffered for applications such as drying without affecting the production flow. Simultaneous production of different formats is possible thanks to the availability of different mover sizes in one system.

Exceptional dynamics and robotic precision qualify XPlanar as an efficient positioning system for processing different batch sizes and product variants. The movers scan complex XY geometries, which also allow individual marking of the transported product on a stationary laser. The geometry is determined individually for each product. The precision of the geometry tracking is so high that complex positioning systems within the processing stations can be omitted.

Conclusion

In conclusion, “the way we have always done things” is not something that needs to continue. Processes and technology to make the factory of the future, allowing for more flexible automation, are here today. Overcoming batch size restrictions, routes to processes and even reducing the number of working stations on a machine, by utilising the 6 degrees of freedom built into such equipment as the XPLANAR, can even simplify or make systems less expensive. SP Automation & Robotics do not accept the status quo and continues to strive to innovate well beyond the norm. The ultimate goal is to provide solutions that suit the application and keep production costs as low as possible whilst maintaining quality.

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