14.2 Robotics in Manufacturing Systems

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

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  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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  EEDURO Delta Robot [The EEROS Education Robotics Platform] 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 throughput
  • 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
• Collaborative robots (cobots) 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