The More Things Change: The Benefits of Flexibility

As consumer demand for new and unique packaging sizes, shapes, and configurations continues to grow, packaging lines must become more flexible. Robotic automation enables the quick and easy changeover needed to switch between product configurations.

 

For example, EPSON Robots, a provider of Selective Compliant Assembly Robot Arm (SCARA) robots, will introduce its new RS4 model, a “zero-footprint robot” that features an expanded work envelope. 

 

“Unique to the EPSON RS4 arm is our new workspace design, which maximizes work envelope usage,” says Michael Ferrara, director, EPSON Robots. “The arm structure utilizes the entire workspace underneath the arm, defeating the ‘old’ SCARA design limitations so there is no dead space in the center of the work envelope.”

 

The unique work envelope allows for greater design flexibility, with over 360 degrees of axis rotation and omni-directional access that make the robot ideal to process heavy applications where large quantities of parts are presented to process or testing stations.

                                                      

The 550mm SCARA arm is capable of working on pallets as large as 778mm x 778mm, and has the ability to maneuver under itself for the shortest possible movements, enabling higher speeds and throughputs. Easy integration into compact assembly cells also reduces the footprint and allows for a greater variety of line configurations.

 

Likewise, C&D Skilled Robotics, Inc. offers a number of palletizing robots that combine with laser-guided vehicles to provide end-of-line automation, emphasizing flexibility in product flow configurations. C&D’s systems automate the transport of products from separate production lines to storage or trucking area. On display at PACK EXPO Las Vegas 2011 will be the SKILLED 504 SCARA robot, which features four interpolated axes with a 360-degree working area. A three-column design allows for more efficient movements and a better use of space, according to Robert Sanders, sales manager, C&D Skilled Robotics. The SKILLED 504 is designed to handle a variety of product types, including cardboard boxes, bundles, shrink-wrapped trays, bags and reels, allowing brand owners to shift usage among a variety of different applications.

 

Additionally, the ability to use a laser-guided system provides increased flexibility in the production layout of the factory floor. Sanders notes that older systems required extensive and permanent or semi-permanent installations on the floor to guide the vehicles for product transport. C&D’s laser-guided vehicles enable brand owners to expand capacity and increase volume as needed and change product paths just by altering the computer programs that guide the system.

 

A three-column design allows for more efficient movements and a better use of space, according to Robert Sanders, sales manager, C&D Skilled Robotics: “In the lifespan of any manufacturing process, you’re going to eventually wanting to add or change paths. The flexibility of our system enables our customers to account for capacity increases with ease and avoids the downtime, changeparts and maintenance associated with conveyor systems.”

 

Bosch Packaging Technology, Inc. has a range of robotic packaging applications that highlight different flexibility features: a variety of Delta arm placements within a robotic cell (1-4 arms in a single cell), multiple cells for larger applications, and control solutions that manage pick-and-place strategies between multiple robotic cell arrangements. Specific robotic applications that Bosch specializes in include primary feed placing solutions that feed into wrapper flights or thermoforming machines; top-loading for tri-seal cartons, trays and cases; and bucket loading for end load cartoning applications.

 

Bosch marketing manager Paul Garms focuses on the simulation capabilities of Bosch’s technology. “Our simulation gives us the ability to determine the number of arms required specific to an application using actual speeds, accelerations, and trajectories to determine rates,” he says.  Additionally, he cites Bosch’s custom -designed end effectors, which are tailored to each application, maximizing picking capabilities and control for various products.

 

At PACK EXPO Las Vegas 2011, Bosch will display a single arm frame with Delta robotics technology and an integrated flow wrapper. Software controlling the Delta Arm features visualization of production and simulation capabilities. The simulation features support cost optimization and allow Bosch to recommend more accurate arm count per application.

 

“The benefits of robotics in packaging are a return-on-investment in terms of months, not years, and higher efficiency in the lines,” Garms says.

 

More Bang for the Buck: Enhancing Productivity and Lowering Labor Costs

 

Automating a packaging process with robotics offers greater speed, accuracy and capacity than the comparable manual processes it tends to replace – and many robotics providers claim that the return-on-investment over time justifies the switch. Adding a robotics component can help minimize labor costs, increase throughput and enable round-the-clock operations, making more productive use of packaging line assets that might otherwise sit idle.

 

Indeed, FANUC Robotics America, Inc. will feature its new M-3iA, an intelligent, parallel-link robot designed for small part handling and picking applications. The robot boasts an increased payload and work envelope compared to the company’s smaller M-1iA robot, offering packagers greater throughput and capacity. Available in a four- or six-axis model, the M-3iA offers the same parallel-link structure as the previous model, and accommodates payloads up to 6kg.

 

Dick Motley, packaging manager, National Distribution Network, FANUC, notes the multiple benefits of robotizing a manufacturing process, ranging from labor savings, capacity improvement and even energy efficiency. Commenting on a recent installation that automated a cooking line, he notes, “Labor savings were just the tip of the iceberg. We achieved an 80 percent capacity improvement and higher utilization of the ovens whereas the earlier arrangement was wasting heat and energy because the manual input was so slow.”

 

Motley explains that robots can increase speed and up capacity and get more use out of existing assets, which in turn can enhance energy efficiency. For example, the process of manually placing bread into an oven can only go at “human speed,” which means the oven door stays open longer, and more heat escapes. Using robotics for the same job moves the bread more quickly, so the heat stays in the oven instead of ‘cooking’ the air.”

 

FANUC’s integrated iRVision’s Snap-in-Motion software, which guides vision systems that support pick-and-place movements, also supports the drive towards higher speeds. Typical vision systems have stationary cameras that require the robot to stop to take a picture, increasing cycle time. The Snap-in-Motion feature of iRVision allows the robot to move the camera over a work area, and snap and locate parts without stopping, helping to reduce cycle times.

 

ABB, Inc. will highlight its IRB 360 FlexPicker, which, according to Joe Campbell, vice president of the ABB Robot Products Group in the United States, is the industry’s first “second generation” delta robot. Attempting to meet the demand for higher productivity, the new robot features a 35 percent smaller footprint, 30–60 percent faster throughput and a 50 percent higher payload than previous models.

 

Campbell notes that “all robots save on labor, or move people from less rewarding, repetitive jobs into jobs with more growth potential and rewards. In addition to savings on labor, there have been recent movements in production facilities to save on space.”

 

He cites the IRC5 Compact controller, an integral part of the IRB FlexPicker, as a key feature enabling higher speeds and precision. The controller is designed to track fast-moving conveyor belts with high accuracy as well as facilitate smarter, leaner robot cells designs and better control of production lines.

 

Campbell also says that an Indexed Conveyor Tracking software feature allows the IRB 360 to accurately follow the motion of an indexing conveyor at rates up to 450 indexes per minute. Designed to reduce the cost and complexity of high speed carton loading applications, it allows the IRB 360 to track many other indexing packaging machine infeeds during the complete index motion, improving system throughput up to 50 percent. 

 

Get with the Program: Software and Information Management Innovations

 

With the dizzying array of technical innovations and enhanced features rapidly coming on to the market, production managers require the tools to control, monitor and manage these systems and track the data they produce. Whether it’s managing product flow speeds, using modeling and simulation software to specify optimal line configuration, or tracking production data to identify inefficiencies, robotics providers are coupling their machines with smart software better enable packagers to achieve their production targets.

 

 

MOTOMAN’s MLX100 Robot Gateway platform is designed with this seamless ease-of-use in mind. The platform enables users to program MOTOMAN robots directly from RSLogix™ software.

 

Tim DeRosett, director of marketing at MOTOMAN, Inc. says that software solutions that provide more and better data – and are better able to exchange data between system components – are critical to companies’ packaging operations.

 

“Interoperability is becoming more and more critical to companies as they try to access production information in real time,” he says.

 

DeRosett also notes that MOTOMAN products provide access to robot production data and feature compatibility with open software platforms.  This provides easy access for programming the robots as well as allowing access to more and more data. 

 

“This makes connectivity across the shop floor and even up to MES [Manufacturing Execution Systems] and ERP [Enterprise Resource Planning] systems seamless,” he adds.

 

DeRosett says that, because the maintenance and engineering staffs at most companies are usually already proficient in RSLogix software, companies can program and support a wide range of industrial robots with their existing staff and without extensive software training. The ability to program the robot from within RSLogix software is meant to offer more possibilities to both packaging machine OEMs and end users. Using PAC/PLC (Programmable Automation Control/Programmable Logic Control) language, the MLX100 allows users to program, deploy and support robotic systems utilizing their existing in-house programming expertise.

 

Rockwell Automation, a provider of automation control and information systems, works with robotics manufacturers to develop control solutions. Leo Petrokonis, business development manager, stresses the benefits of using one integrated control system for an entire packaging line. “If the same technology and software is used throughout the plant, then maintenance, storage, training, and spare parts are the same, simplifying a whole range of operations,” he says. Unifying the control function under one system also enables different components to “talk to each other better” and minimizes the specialization needed to repair and maintain the line.

 

The benefit of integration through unified control platforms is a key focus of Rockwell’s Kinematics Integrated Motion Solution. Designed for robot control, Kinematics helps OEMs and end users to unify all control functions as part of a single, integrated solution, eliminating the additional robot and safety controllers, software and custom modules typically required when incorporating a robot into an application. This approach allows users to utilize the same hardware and software architecture to help control the discrete, motion, safety and robot sections of their packaging lines. Petrokonis says users can save time and reduce training costs with a unified hardware that uses a common programming software and language for the entire application. The control system also is able to synchronize robotic motions with other components of the line; e.g, a vision system or a conveyor.

 

Easy to be Green? Sustainability Still Sells

Sustainability themes are a staple on the processing and packaging scene. Robotics manufacturers are keenly aware of this and attacking the associated challenges in ways that are environmentally sound and make good business sense, such as minimizing the energy usage of a piece of equipment or reducing packaging waste through the prevention of dropped products with precision handling capabilities.

 

Terry Zarnowski, director of sales and marketing, Schneider Packaging Equipment Co., Inc., a designer of “complete end-of-line solutions,” observes that sustainability is key in the minds of his customers when sourcing robotics solutions. 

 

“Our designs utilize less energy through a process of ‘right-sizing’ the equipment to match the needs of the application,” he says. Schneider delivers designs emphasizing flexibility and adaptability to ensure the maximum amount of product can be packed in a given area, reducing packing material needs as well as the volume occupied on a truck or shipping container. Zarnowski adds that this approach improves overall sustainability, lower costs and increased profitability.

 

Schneider will display an application demonstrating just this effect at PACK EXPO Las Vegas 2011. A robotic carton loading cell utilizing vision-guided robots will feature high speed picking of randomly located bags on a conveyor and load them in a nested fashion into a carton. Zarnowski underlines that this allows for the densest possible packing of products and thereby reduces the amount of packaging materials.

 

But other approaches to sustainability abound. FANUC’s Motley explains that the higher equipment availability and shorter changeover times associated with robotics applications increase plant efficiency by not wasting electricity and other resources on powering the plant when the line isn’t running. Alternatively, Sanders of C&D sees sustainability in the “super-efficient” motors, servos and drives built into the company’s equipment, as well as their use of gel-based batteries, which put out a waste product less harmful to the environment than do air-based batteries.

 

MOTOMAN builds sustainability into its controls system, which includes a hibernation feature that powers down the servo motors and drives when the robot is not in production mode. And Campbell of ABB points to the precision movements of their robots, which helps cut down on product waste.

 

 

 

Source: www.mbtmag.com