14.2 Robotics in Manufacturing Systems
5 min read•july 30, 2024
Robotics in manufacturing systems revolutionizes production processes, boosting efficiency and quality. From articulated robots welding car bodies to delta robots packaging food, these machines transform industries. Their versatility and precision make them indispensable in modern factories.
Robotic systems combine mechanical components, sensors, and advanced control systems to perform complex tasks. By improving productivity, enhancing safety, and offering long-term economic benefits, robots are reshaping the manufacturing landscape. Their impact extends beyond the factory floor, influencing product quality and business competitiveness.
Robot Types and Applications
Industrial Robot Classifications
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Top images from around the web for Industrial Robot Classifications
EEDURO Delta Robot [The EEROS Education Robotics Platform] View original
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File:KUKA Industrial Robots IR.jpg - Wikimedia Commons View original
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File:TOSY Parallel Robot.JPG - Wikimedia Commons View original
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- Industrial robots classified based on mechanical structure
- Articulated
- SCARA
- Cartesian
- Cylindrical
- Delta
- Articulated robots feature multi-jointed arm structure
- Versatile for various tasks (welding, painting, assembly)
- Commonly used in automotive manufacturing
- SCARA (Selective Compliance Assembly Robot Arm) robots excel in high-speed operations
- Ideal for pick-and-place tasks
- Frequently employed in electronics assembly
- Cartesian robots operate on three linear axes
- Also known as gantry robots
- Suitable for large work envelopes (CNC machining, 3D printing)
- Cylindrical robots combine rotary and linear motions
- Effective for handling machine tools
- Well-suited for assembly operations in confined spaces
- Delta robots utilize parallel link structure
- Designed for high-speed applications
- Commonly used in sorting and packaging (food industry, pharmaceutical industry)
Application Examples
- Articulated robots in automotive manufacturing
- Spot welding car body panels
- Applying paint to vehicle exteriors
- Assembling engine components
- SCARA robots in electronics manufacturing
- Placing components on circuit boards
- Soldering small electronic parts
- Testing finished products
- Cartesian robots in additive manufacturing
- 3D printing large-scale objects (architectural models, furniture prototypes)
- CNC machining of metal parts for aerospace industry
- Cylindrical robots in machine tending
- Loading and unloading materials from lathes
- Transferring parts between machining stations
- Delta robots in food packaging
- Sorting candies by color and shape
- Placing baked goods into packaging trays
Robotic System Components
Mechanical and Actuator Components
- Mechanical structure consists of links, joints, and end-effectors
- Determines robot's degrees of freedom and workspace
- Links connect joints and form the robot's main body
- Joints enable movement between links
- Rotary joints allow rotation around an axis
- Prismatic joints permit linear motion
- End-effectors attached to robot's wrist to perform specific tasks
- Grippers for picking and placing objects
- Welding torches for joining metal parts
- Spray nozzles for painting or coating applications
- Actuators provide power to move robot's joints and manipulate objects
- Electric motors (servo motors, stepper motors)
- Hydraulic systems for high-force applications
- Pneumatic systems for lightweight, fast movements
Sensor and Control Systems
- Sensors provide feedback on robot's position, orientation, and environment
- Encoders measure joint angles and positions
- Force/torque sensors detect applied forces and moments
- Vision systems capture and process visual information
- Robot controller functions as the system's "brain"
- Processes sensor data
- Executes programmed instructions
- Coordinates robot movements
- Programming interfaces allow operators to define and modify tasks
- Teach pendants for on-site programming
- Offline programming software for complex path planning
- Safety systems ensure safe operation around humans
- Light curtains detect human presence in work area
- Pressure-sensitive mats trigger emergency stops
- Emergency stop buttons for manual intervention
Robotics Impact on Manufacturing
Efficiency and Productivity Improvements
- Robotic systems significantly increase production rates and
- Operate continuously with minimal downtime
- Perform tasks faster and more consistently than human workers
- Reduce cycle times in manufacturing processes
- Optimize movement paths for efficient operation
- Eliminate time wasted on non-value-added activities
- Increase production flexibility
- Quick changeovers between different product lines
- Easily reprogrammed for new tasks or products
- Facilitate implementation of lean manufacturing principles
- Just-in-time production reduces inventory costs
- Optimize material flow throughout the facility
- enable human-robot interaction
- Combine cognitive abilities of humans with precision of robots
- Enhance overall process efficiency in tasks requiring human judgment
Quality and Safety Enhancements
- Robots enhance product quality through high precision and consistency
- Reduce human error and variability in manufacturing processes
- Maintain uniform quality across large production runs
- Advanced robotic systems enable real-time quality control
- Machine vision detects defects in products
- AI algorithms analyze and classify quality issues
- Improve workplace safety by handling hazardous tasks
- Manipulate dangerous materials (chemicals, hot metals)
- Perform repetitive motions that can cause strain injuries in humans
- Reduce the risk of accidents in manufacturing environments
- Robots operate predictably and follow safety protocols
- Integrated safety systems prevent collisions with humans
Economic Justification for Robots
Cost Considerations and ROI
- Initial investment costs for robotic systems include
- Hardware acquisition (robot arms, controllers, end-effectors)
- Software integration and customization
- Facility modifications (safety barriers, power supply upgrades)
- Employee training programs
- Return on Investment (ROI) calculations consider multiple factors
- Increased productivity and output
- Reduced labor costs across multiple shifts
- Improved product quality and reduced scrap rates
- Decreased waste in manufacturing processes
- Payback period typically ranges from 1 to 3 years
- Varies depending on application complexity
- Shorter for high-volume, repetitive tasks
- Labor cost savings often significant in economic justification
- Robots can replace multiple human workers across shifts
- Reduce overtime and associated labor costs
Long-term Economic Benefits
- Improved product quality leads to long-term cost savings
- Reduced warranty claims from customers
- Fewer product returns and associated processing costs
- Enhanced brand reputation and customer loyalty
- Flexibility and scalability of robotic systems offer future advantages
- Easier adaptation to changing market demands
- Potential reduction in future capital expenditures
- Indirect economic benefits contribute to overall savings
- Reduced workplace injuries lower insurance premiums
- Improved employee satisfaction by eliminating repetitive tasks
- Enhanced company image as a technologically advanced manufacturer
- Potential for new business opportunities
- Ability to take on more complex or high-precision projects
- Increased capacity to meet larger production volumes
Key Terms to Review (21)
Articulated robot: An articulated robot is a type of robotic arm that features rotary joints, allowing for a range of movement similar to that of a human arm. These robots can have multiple joints and are known for their flexibility and dexterity, making them ideal for various tasks in manufacturing systems, such as assembly, welding, and material handling. Their design enables them to reach and manipulate objects in three-dimensional space, enhancing productivity and precision in industrial applications.
Assembly line automation: Assembly line automation refers to the use of advanced technology, such as robotics and computer-controlled systems, to streamline and enhance the production process in manufacturing. This approach increases efficiency, reduces labor costs, and improves product quality by minimizing human error and optimizing workflows. The integration of automation into assembly lines plays a crucial role in modern manufacturing systems, enabling higher output rates and adaptability to changing production demands.
Cartesian Robot: A Cartesian robot is a type of robotic arm that operates on three linear axes, typically aligned with the X, Y, and Z coordinates of a Cartesian coordinate system. This design allows for precise movements in a straight line, making it ideal for applications such as pick-and-place operations, assembly, and machining in manufacturing systems. The simplicity of its movement and control makes Cartesian robots easy to program and integrate into various manufacturing processes.
Collaborative Robots (Cobots): Collaborative robots, or cobots, are designed to work alongside human operators in a shared workspace. Unlike traditional industrial robots that often operate in isolation for safety reasons, cobots are equipped with advanced sensors and software that enable them to safely interact with humans, enhancing productivity and flexibility in manufacturing environments.
Cycle Time: Cycle time refers to the total time it takes to complete one cycle of a process from start to finish. This includes every step in the process, from the initiation of a task to its completion, and is crucial for understanding efficiency and productivity in various systems.
Cylindrical robot: A cylindrical robot is a type of industrial robot that operates within a cylindrical coordinate system, characterized by a rotary base and an arm that can extend vertically and horizontally. This design allows for flexible movement in a limited range, making it suitable for tasks such as assembly, welding, and material handling in manufacturing environments. The cylindrical structure enables these robots to navigate around obstacles while providing a defined workspace for efficient operations.
Delta robot: A delta robot is a type of parallel robot that consists of three arms connected to a common base, designed for high-speed pick-and-place tasks. Its unique configuration allows for rapid movements and precise positioning, making it ideal for applications in manufacturing and assembly processes.
End effector: An end effector is a device attached to the end of a robotic arm that interacts with the environment to perform tasks such as grasping, manipulating, or assembling objects. It plays a crucial role in the functionality of robotic systems by allowing robots to execute specific tasks in manufacturing and production processes, such as welding, painting, or assembly. The design and type of end effector can vary significantly based on the application and required precision, which makes it a fundamental component in robotics.
Flexible Manufacturing Systems: Flexible Manufacturing Systems (FMS) are production systems that can be easily adapted to handle different products with minimal downtime. This adaptability allows manufacturers to respond quickly to changing market demands and production requirements. The integration of robotics within these systems enhances efficiency and precision, enabling faster production cycles while maintaining high quality.
ISO 10218: ISO 10218 is an international standard that outlines safety requirements for industrial robots, focusing on the design and manufacturing aspects to ensure a safe working environment. This standard is critical in the context of robotics in manufacturing systems as it aims to minimize risks associated with the operation of robots and enhance overall safety in automated workplaces. It helps organizations establish safety protocols and guidelines when integrating robotic systems into their production processes.
Material handling: Material handling refers to the movement, protection, storage, and control of materials and products throughout the manufacturing and distribution process. It encompasses the equipment, systems, and methods used to transport materials from one location to another, which is crucial in optimizing efficiency and minimizing waste in production environments. The integration of material handling with robotics in manufacturing systems enhances productivity by automating these processes, ensuring faster and safer handling of materials.
Puma Robot: The Puma Robot is a type of robotic manipulator originally developed in the 1970s, specifically designed for use in industrial applications such as manufacturing and assembly. Known for its precision and flexibility, the Puma Robot can perform a variety of tasks including welding, painting, and material handling, making it a vital component in robotics within manufacturing systems.
Robot Operating System (ROS): Robot Operating System (ROS) is an open-source framework designed for building robot software. It provides a set of tools, libraries, and conventions to simplify the development and management of complex robotic systems, making it easier for developers to integrate various components and functionalities into robots. Its modular architecture allows for easy communication between different parts of a robotic system, which is essential in manufacturing environments where robots often need to work together or with other machines.
Robotic automation: Robotic automation refers to the use of robots and automated systems to perform tasks in manufacturing processes, enhancing efficiency and precision while reducing human intervention. This technology allows for consistent production, improved safety, and the ability to operate in environments that may be hazardous for human workers. With advancements in artificial intelligence and machine learning, robotic automation is becoming increasingly sophisticated, allowing for more complex tasks and integration into various manufacturing systems.
Robotic controller: A robotic controller is a specialized computer system that manages and coordinates the actions of a robot, ensuring that it performs tasks accurately and efficiently. This controller interprets commands, processes input from various sensors, and communicates with the robot's motors and actuators to execute complex movements in manufacturing processes. Its functionality is crucial in automating tasks, improving productivity, and maintaining precision in robotic operations.
Robotics design principles: Robotics design principles are the fundamental guidelines and considerations that engineers and designers follow to create effective, efficient, and reliable robotic systems. These principles focus on optimizing the functionality, safety, and usability of robots in various applications, particularly in manufacturing systems where precision, adaptability, and performance are critical for success.
Safety Interlock Systems: Safety interlock systems are mechanisms designed to prevent the operation of equipment unless certain safety conditions are met. These systems ensure that dangerous machinery or robotic operations cannot be activated until specific criteria, such as door closures or safety guard placements, are satisfied, thus reducing the risk of accidents in manufacturing environments.
SCARA Robot: A SCARA (Selective Compliance Assembly Robot Arm) robot is a type of industrial robot known for its ability to perform precise and repeatable tasks in a horizontal plane. With its unique design featuring two parallel rotary joints, the SCARA robot excels in assembly, pick-and-place operations, and other tasks requiring high speed and accuracy, making it an essential component in many manufacturing systems.
Task allocation algorithms: Task allocation algorithms are systematic methods used to assign tasks or jobs to different agents or resources in a way that optimizes performance and efficiency. These algorithms are crucial in various systems, especially those involving automation and robotics, as they help in determining how best to utilize available resources while minimizing costs and maximizing productivity.
Throughput: Throughput refers to the rate at which a system produces output or completes tasks over a specified period. It is a crucial measure of efficiency in operations, as it helps organizations understand how effectively resources are being utilized to meet demand.
Unimate: Unimate is the name of the first industrial robot, developed in the 1960s by George Devol and later manufactured by the company Unimation. This revolutionary machine was designed to automate repetitive tasks in manufacturing, significantly enhancing production efficiency and accuracy. Unimate paved the way for the widespread adoption of robotics in various industries, marking a pivotal moment in the evolution of manufacturing systems.