Machine loading automation at manufacturing companies. On vision systems, grippers and conveyors
Machine loading automation is often at the bottom of the priority list at manufacturing companies. Or it has even disappeared from that list altogether. Because it is deemed too expensive. Or the process is regarded as impossible to automate. But just because there is no standard solution does not mean it cannot be done, or that the business case is flawed. This article zooms in on three solutions that are creating new opportunities for your machine loading automation.
Let’s start with one of our exploratory customer visits. During such a visit, we go on site to get a clear view of the scope of the assignment.
We step in when the customer starts outlining their project. And as is often the case, machine loading is not in the picture.
Production company
The first step is to pick these cast iron parts. This conveyor belt then rolls them in.
Us
And how do these parts get onto that belt?
Production company
An operator takes them out a large wooden crate one by one, and then places them on the belt.
Us
Why wouldn’t this be step one of your future machine? Automated picking of the parts, straight from the crate?
Manufacturing company
I don’t think that would be possible. The parts are unsorted. And if we have to let the operator sort them out first, he might as well put them on the belt.
In this case, the scope of the assignment was to design and build a custom assembly machine.
But whatever the exact scope, one part of the production process is often the same: sorting out bulk parts for transport. For the latter, a standard conveyor belt suffices in most cases.
The limits of standard solutions
The real challenge lies in the parts’ complex shape. This is where off-the-shelf robot hands or cobots often fall short. Because the precise dimensions of the parts vary too much, or because the parts are too heavy, too light and so on.
Also often part of the challenge: the disorder of the bulk.
Even if a standard gripper could handle the shape, it wouldn’t know where to start. Classic vision technology does not see which part is the logical choice to pick first.
A challenge for machine loading automation: a tangle of parts. Photo: PickIt Therefore, machine loading is entrusted to an operator. While technically, technologically and business-wise, it is often perfectly possible to automate this part of the process as well.
Pushing boundaries
Three technologies play an important role in this solution: vision systems, grippers and conveyors.
1. Improved vision systems
Vision systems have improved enormously in recent years. Image quality has gotten better. Combined with deep learning, this allows us to develop solutions for applications where classic vision systems typically fail.
Bringing order to chaos. Foto: PickIt. That combination of better image quality and machine learning makes it possible to integrate a vision system capable of bringing order out of chaos. That, firstly, can determine the correct picking order. And secondly, understand how each part is orientated.
2. Custom robot grippers
An off-the-shelf robot or cobot offer great automation possibilities. But standard grippers simply cannot handle certain parts.
In those cases, a customer gripper might be the solution. We design and build a gripper specifically for your production parts. With customised mechanics and programming.
A custom gripper system for machine loading automation. The theory is discussed in the article Customized robotic gripper: the step to 100% automation.
This cobot, that helps assemble washing machines, puts that theory into practice. The robot arm itself is off-the-shelf, the gripper completely custom. Result: a solution that lifts a 25-kilogram counterweight and then positions it very precisely. The operator just needs to screw the bolts.
In other cases, a chute can be the solution. As in this machine, where a chute sorts out metal bars one by one in a controlled manner.
3. Customised conveyors
That previous case is interesting for another reason: the custom-built conveyor.
Further down the line. Ready for a final check. Such a customised conveyor can also be part of the solution. When precise positioning is crucial, for example. In the previous machine, two small springs, each on one side, grip hold of the bar. Firm enough to hold it in place, but at the same time leaving enough space to manoeuvre it.
Machine loading automation: conclusion?
We firmly believe that we can design and build a solution for every machine loading automation challenge. And that with the right design choices, we can make your business case work out.