The Starting Point for Robot AutomationA Beginner’s Tour

Presenter:Rick BrookshireProduct Development Director

August 2019

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Robotics Today

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Automotive

Consumer Electronic Electronics

Medical

LabAutomation

Industrial

Robots are used in a wide variety of industries and applications

Industries

Applications Complex – high precision (< 10 microns); high speed (< 1 cycles)Simple – pick & place, material handling1000’s of different applications

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Starting Point for Automation

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I want / need to Automate

Not sure how to get started

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5 Key Focus Areas

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AREAS TO DEFINE / EXAMINEBefore & while talking to Robot Vendors or System Integrators

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Why automate?

Define your current process

Identify your requirements

Automation components

Manpower

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Why Automate?

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1What is the Driving Factor?

Organizational alignment on why to automate is a critical success factor

Cost

Volume

Quality

Precision

Safety

Do you need to reduce your current cost per unit?

Do you see an increase in demand, but lack the resources to meet the volume requirements?

Are your deliverables turning out perfectly every time, or are there quality issues?

Are your parts too small or precision requirements too tight for humans to handle?

Are the materials you are handling unsafe for humans? Are repetitive motions causing human injury?

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Define Your Process

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Automation Success requires People,

Technology & Process

People

Technology

Process

Make sure you have experienced automation resources

Technology alone will not solve your problems. (Use the right products for the application)

A clear definition of your process drives the technology and defines the skills (people) required for the application

Technology

People

Process

Success

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Define (Know) Your Process

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Clear current process definition is a critical

success factor

How do you “do it” today?• Is the process documented?• Can you explain it clearly (step by step)?• Think about things like part supply/feeding, special

jigs/fixtures, etc.

Identify the “Problem Areas”• Define the toughest problem areas• What is slowing down your current process? (Which

steps take the most time and why?)• Do you have too many reworks? Why?• Product Volume? Product Quality?

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Process Example2Building Electric OutletsPotential Problem Areas

Variety of products• Are there possibilities of using the wrong parts due to variety of products?

Deviation of Part Tolerances• Have you verified part specs and variances?

Proper Part Insertion• Right side up issue. Skewed insertion. Proper seating…

Fastening Issues• Part alignment during fastening. Screw driving issues like stripping, broken

screws, etc. Snap fit issues. (Did the parts secure properly?)

Know your potential problem areas to help improve quality

& cycle times

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Identify Your Requirements3

Speed Speed

PerfectWorld Reality

Speed Precision PayloadTradeoffs:

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Identify Your Requirements3Cycle TimeThink Big Picture – How many parts do you need per day?

What’s Next?• Calculate system cycle time requirements. Use experienced automation resources. • Work with System Integrators and Robot vendors to calculate system cycle time

requirements.• Why? They will include critical things like dwell time for grippers, tool change times, part

transfer times, vision processing time, and much more.

Maximize Cycle TimeA few ways to maximize cycle times are:• Select the fastest robots for the application (SCARA vs. 6-Axis vs. Delta, etc.)• Layout is critical for cycle time. Work with experts early. Not after your system is almost done

and can’t meet your target cycle times.• Use multi-headed tooling• Use motion and software optimization techniques

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Identify Your Requirements

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3PRECISION What precision is required to successfully assemble parts? How you come up with

a number is critical for total system success.

START WITH THE PARTS• What is the application you are doing? Battery insertion into a carrier (lower precision) or precision pin insertion

(higher precision)? • What is the tightest fit for parts in the process? • Add a buffer to cover part placement tolerance issues

TOLERANCES• Consider all aspects of the system as tolerance buildup can cause poor assemblies • Part to part variance (part precision)• Feeding method and precision• Tooling – Will the part move? • Cabling – Will the cables bind or pull at the tooling?• Robot precision and motion

IMPROVE PRECISION WITH OPTIONS• Use Vision Guidance to adjust for part pickup and placement deviations• Use Force Guidance for ultra precise placement requirements

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Identify Your Requirements3PAYLOADDetermining the total payload required for your application.

Payload is more than part weight Common issue is to underestimate or forget about all aspects of what will be moved around during an assembly process. Be sure to spec for total payload and not just part weights.

Payload calculations should include • Parts – Many times the smallest component of “payload” calculation • Tooling – Most of the time (for small high precision applications) the end-of-arm tooling

weighs more than the parts. • Peripherals attached to the robot – vacuum generators, cabling, etc.

Note: Also consider offset of tooling due to robot inertia limits

Epson Precision Core Print Head Assembly(Epson C4L Clean/ESD 6-Axis Robot)

Payloads can affect cycle times and precision. Sometimes requiring moving up to larger robots (even with small parts) to hit cycle times.

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Identify Your Requirements3REACH/SIZE OF WORK AREAHow much space do you need for the workcell process?

Consider Layout, Peripherals And Entire Process Peripherals, carriers and process usually dictate workcell size. Not the actual parts.

Perform Layout Optimization Process Up Front • Longest motion – critical for work area determination• Common motion – important for optimizing total cycle time• Robot mounting – Table top, ceiling mount, wall mount• Peripherals and locations• Conveyors and other forms of part transfer systems• Pallets, trays and other carriers• Z heights – Sometimes dictates robot selection• Tool offsets – Make sure robot can get to locations with tool offsets (rotation can be an issue)

Photo courtesy of Janssen Ortho(Blister Pack Loading)

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Automation Components

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4CONSIDERATIONS BEFORE AUTOMATING

PARTS PRESENTATION• How will parts get to the robot?• Bowl feeders, Flexible Feeders, Conveyors…• Specialized fixtures to hold or orient parts (like flip tools)

VISION / FORCE SENSING• Are parts presented consistently or is there deviation?• Vision guidance - to handle part and position deviations and inspect for proper placement• Force guidance - helps drive high precision placement and provide feedback/quality data

END-OF-ARM TOOLING• How will you pickup parts?• Type of Tooling - simple pneumatic, mechanical gripper, specialized tooling • Most applications require specialized tooling. Consult/use a specialist.• Tool Changers, Multi-headed tooling considerations

Epson G3 SCARA Robot shown with mounted mobile camera as part of Epson

Vision Guide option

Define up front what peripherals will be required for your

workcell

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Automation Components

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4CONSIDERATIONS BEFORE AUTOMATING

FACTORY STANDARDS• Are there standards you must follow?• Vendor standards due to already having equipment in house• Communication standards – Ethernet/IP, EtherCAT, DeviceNet, etc.• Component standards (trays, conveyors, PLC usage, etc.)

ROBOT BASEConsider the structural requirements• Base Rigidity• Are robots mounted from ceiling, tabletop or floor? • Peripheral equipment mounting (is isolation required?)• Precision, speed and payload play a factor in base requirements• Define your layout before purchasing a base

Photo courtesy of RND Automation

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Manpower

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5WHO WILL BUILD YOUR SYSTEM?

RESOURCES REQUIREDWhat type people will be needed?• Mechanical Engineers, Controls Engineers, Software Engineers, Process Specialists• Project Manager

INTERNAL OR EXTERNAL RESOURCES• System Integrators• In house automation groups• Newbies

ASK FOR HELP• Don’t try to do everything yourself • Robot vendors are a great source of knowledge in nearly all aspects of workcell design • Areas to ask for help - Planning, Layout, Cycle time estimates, Tooling, Optimization, etc.

The proper resources will make or break your project

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Summary

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FOCUS ON THE 5 KEY AREAS OF PREPARATION

Clearly define the reason(s) for automating and get organizational alignment

Define and document your current process (to share/explain to others)

Identify your requirements (Cycle Time, Precision, Payload, Reach)

Automation Components. (Parts presentation, End-of-Arm Tooling, Vision/Force Guidance, Factory Standards, Robot Base)

Manpower – System Integrator or In-house? Use experts when possible.

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Visit Epson RobotsPack Expo Booth # LS-5989

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Thank you!For more information, please visit Epsonrobots.com