Automation through machine is widespread in manufacturing in the metalworking world and consistently evolving with technologies such as Industry 4.0, Data Analytics and Predictive Maintenance. Nonetheless, machine shop operator should not jump into panic mode assuming the latter developments will take their place.
EMO Hannover 2023 Scores With Innovative Solutions For Today’s Challenges
A spectacular display of innovations, high levels of global visitor interest, and a great atmosphere in the halls: “After four years, the relaunch has been a huge success for EMO Hannover,” sums up EMO Commissioner General Carl Martin Welcker after six days in Hannover.
Industrial Control Strengthens Kassow Robots’ Solutions and Education Platform
The combination of Kassow Robots’ KR series of 7-axis cobots and Industrial Control’s solutions allows humans and robots to work together to efficiently complete repetitive tasks and those that require the highest accuracy, such as quality assurance.
Living Skin Layer for Robots and Prostheses
Researchers at the University of Tokyo have developed a method to coat a robotic finger in a living “skin” layer. The living coating is strong and flexible enough to allow the robotic finger to bend and flex, and it can repel water and even self-heal if damaged.
Cobots Continue To Gain Interest For Flexible Automation, Tipping The Market Over US$600 Million In 2021
Despite the challenges facing the wider manufacturing industry during the coronavirus pandemic, collaborative robots continue to attract attention and investment, due to their ease of use, redeployability, and convenience to end-users who struggle to afford more traditional forms of automation.
According to a new report from global tech market advisory firm ABI Research, the cobot market is set to grow substantially over the coming decade. The market had a global valuation of US$475 million in 2020, which will expand to US$600 million in 2021 and US$8 billion in 2030, with a projected CAGR of 32.5 percent.
“The most direct benefit of cobots is not in their ability to collaborate with humans”, said Rian Whitton, Principal Analyst at ABI Research. “Rather, it is in their relative ease of use, improved interface, and the ability of end-users to redeploy them for different tasks”. This has made cobots popular with small and medium-sized enterprises (SME’s) which value flexibility and incremental automation where the maintenance cost is not prohibitive.
Universal Robots is currently the dominant player in the market, with 50 percent of the total shipments and posting US$219 revenue for 2020, but challengers like FANUC, ABB, and others are beginning to catch up after initially lagging in the space. They have done this by improving user interface and the usability of their systems
“The barriers between cobots and standard industrial robots are beginning to breakdown, as many vendors are experimenting with dual-mode robots that can have a cobot and industrial mode. What is more, cobots are beginning to develop heavier payloads, in line with evolving regulations” said Whitton. ABI Research projects that cobots are going to significantly expand the potential for automation for SMEs, while also enabling large vendors to develop a more flexible production line based on movable platforms and no need for fencing. The major industrial automation vendors will enjoy a greater share of the market as they utilise their existing partnerships and pour more resources into new cobot products.
Check these articles out:
2021 Metals Analysis Outlook: Optimising Production Through Connectivity
Collaborative Robotics Market Value To Reach $9.7 Billion By 2025
Doosan Robotics Launches New Cobots Including Support For Machine Tools
For other exclusive articles, visit www.equipment-news.com.
WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!
FOLLOW US ON: LinkedIn, Facebook, Twitter
Reducing Costs And Scrappage From Porosity Through Robotic Vacuum Impregnation
For automotive manufacturers, cost control and quality are vital when it comes to high volume and critical engine components. Bob Remler, Technical Sales Manager in North America at Ultraseal International, discusses how one manufacturer managed to reduce costs and improve operational performance by using robotic vacuum impregnation to seal porosity, minimise scrappage and increase throughput.
Trends and challenges
It is no surprise to learn that the automotive industry in the US is the single largest sector for metal die casting. In today’s vehicles, a high proportion of components – including cylinder heads, engine blocks, transmission cases, e-motor housings, and structural parts – are produced using high pressure die casting processes.
As the industry faces the ongoing challenge of reducing environmental emissions, increasing fuel economy and delivering better performance, manufacturers are seeking methods to reduce vehicle weight and improve overall efficiency. As a result, many are turning to a combination of thinner walled castings and using lighter weight metals such as aluminium and magnesium.
Hand in hand with the move to new production methods and significant research into new casting processes and techniques, comes the shift towards automation. Industry 4.0 is defining the competitive landscape of the industry, with many automotive manufacturers and OEMs turning to digital transformation initiatives to drive efficiencies through their manufacturing processes. This includes smart factories to ‘cobotics’ (the name given to the collaboration between a person and a robot), digital supply networks, artificial intelligence and automation of repetitive processes.
However, while some industry pain points are removed as manufacturing technology and processes evolve, one legacy challenge remains – that of porosity. Porosity is one of the defects most frequently encountered in aluminium die casting. These microscopic voids reduce the density of components, leading to leaks. For parts that go into applications which need to be air or fluid-tight – for example in fuel or cooling systems – this can be an especially critical issue.
Untreated, casting porosity leads to costly scrappage, creating waste inefficiencies in materials, energy and production time.
Specific Challenges Faced by a Respected Engine Manufacturer
For a leading US based manufacturer of engines, off-road vehicles and motorbikes, creating best-in-class vehicles and achieving operational excellence is key to its operating ethos and continued success.
To continue reading this article, head on over to our Ebook!
Check these articles out:
Lumenium To Cut Product Development Time By 25 Percent
Automation Trends in Metalworking
The Best Manufacturing Technology Trends From 2020
New Trends and Opportunities on the Road to Electromobility
For other exclusive articles, visit www.equipment-news.com.
WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!
FOLLOW US ON: LinkedIn, Facebook, Twitter
168 Motion Plastics Innovations From The Home Office
In a difficult environment, more innovations than last year – from the integrated robot drive up to the ball bearing with 21 times the service life
igus increases the pace of innovation despite the pandemic: high investments in digitalisation, logistics and remote consulting increased online sales by 30 per cent in 2020 and mitigated the decline in sales by 4.8 per cent. The motion plastics specialist is also breaking new ground in terms of sustainability and product innovation, and will be presenting more innovations than ever before with 168 tribo-polymer products in spring 2021.
Last year, the turnover of the motion plastics specialist igus fell by 4.8 per cent to 727 million euros in the wake of the Corona crisis. The company is optimistic for the current year, thanks to a significant increase in incoming orders. In addition, the pandemic period has led to a surge in innovation when working from home. The result is 168 new products, product extensions and digital offers this spring, more than ever before. igus will be giving a first preview at the Hannover Messe Digital Edition. The company will also be presenting all its spring news at its own physical-virtual trade show. It has just been awarded the “iF Design Award” and will be completely renewed for visitors from 5th May.
ReBeL accelerates cost-effective automation
After two years of development, the ReBeL, a new robot drive element, can be seen at the igus exhibition. Customers can construct their own robot arms quickly and cost-effectively from the modular kit. The core of the ReBeL is a greatly improved plastic gearbox. An integrated BLDC electric motor with power electronics can be connected to various controls. In addition, a suitable low-cost control system from igus is available free of charge as a download, so that the automation can be simulated in advance. In the field of “large” industrial robotics, igus is launching the TRX energy supply system, a solution that rethinks the subject of robot hose packs. The energy supply system twists, lengthens and shortens in a spiral, and cables are inserted in the form of a spiral. This enables a weight saving of 83 per cent on the 3rd axis, in less than half the space.
Dry-operating ball bearings with 21 times the service life
igus will also be presenting news in all areas of lubrication-free and maintenance-free bearing technology. In the case of ball bearings, the engineers at igus achieved a breakthrough in service life. In the application cases of low loads and high speeds, this was increased by a factor of 21. “What used to last a month now lasts almost two years”, explains Lena Woelke, the Development Manager for xiros ball bearings. Applications are found especially in fans or centrifuges
Plastic becomes a sustainable resource
How these lubrication-free plastic products not only have less impact on the environment during use, but are also produced in a CO2 neutral manner and recycled afterwards is part of the igus mission. The new factory building currently under construction will be climate neutral from the outset, and this will apply to the entire igus factory by 2025. To further reduce emissions, igus invests in modern technologies, for example, in extraction systems and filters; injection moulding machines that save up to 40 per cent energy and are barely audible have been purchased in large numbers. In addition to mechanical recycling in the chainge product range, igus also relies on new types of chemical recycling. Thus, igus increased its investment in Mura Technology to 5 million euros. Mura’s HydroPRS technology converts plastic waste back into oil. Investments increased by 29 per cent overall in 2020.
Investments in digitalisation and capacities bring customers forward
A significant part of the investments went into online shops and online tools. All webshops were renewed and made more informative for customers. New online tools for the configuration and calculation of gears, rollers, linear modules and stepper motors are accessible on the Internet free of charge and without registration. At the same time, igus expanded its stock at every location in the world. In addition to the USA with 23,000 individual parts and Europe with 88,000, 21,000 parts are now available in China in 24 to 48 hours and are assembled by igus in millions of models. The offer of easy online configuration and ordering together with the short delivery time was welcomed by many customers. Online sales increased by 30 per cent worldwide. The early expansion of machine and raw material warehouse capacities from the 3rd quarter of 2020 still ensures fast delivery times in the phase of a rapid economic recovery now.
Change as a duty and an opportunity
“Politics, technology, mobility, entertainment, climate and health – the world is changing rapidly at the moment”, says igus CEO Frank Blase. “We want to be active shapers. So I am proud of the igus colleagues for how they have applied themselves, changed and improved during these times.” The teams have been working predominantly from home since 13th March 2020. The offer for a self-determined quota of home office days with few rules and precise measurability is provided by igus until the end of 2022. At the same time, the company is experimenting with new work spaces and forms of on-site collaboration. “For our industry, the fact that everything is changing, absolutely everything, means everyone is making new products, and everyone needs new machines. This can trigger an enormous boom for our customers and us in the next few years.”
For other exclusive articles, visit www.equipment-news.com.
WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!
FOLLOW US ON: LinkedIn, Facebook, Twitter
Automation On Demand
Bystronic’s Bendikt Kreisel describes the benefits of a fully automatic bending cell in today’s sheet metal processing.
Not long ago, automation was associated only with repetitive tasks. High and consistent quality as well as reliability over very long periods are decisive factors that ensure the profitability of automation in production environments. However, more complex jobs that require a high degree of customisation in the manufacturing process are still often performed manually. This is currently a widespread approach in the sheet metal processing sector.
Our industry has experienced a major transformation over the past five years–indeed, one could say it has been forced to transform. Increasing price pressure in the markets and the lack of skilled personnel are just two of the reasons for this, in addition to increasingly dynamic and uncertain business environments.
Automation Backlog
However, the unique advantages and disadvantages of manual processing by a human operator and automated manufacturing cannot be dismissed. Every decision in favor of or against automating a process is a balancing act involving many production-relevant variables. Besides productivity and quality, flexibility is another undeniable competitive advantage of any supplier in the manufacturing industry, especially in view of increasingly dynamic business environments.
This is a dilemma that has led to a backlog of automation, especially in the sheet metal processing industry. However, when users do not wish to accept any compromises in terms of flexibility, productivity, and consistent high quality, the demands on the machines increase.
Intelligent Technology Solution
Bystronic’s Mobile Bending Cell addresses these demands and implements them by applying intelligent technology. The users’ requirements are particularly wide-ranging when it comes to bending technology. Being able to bend parts with extremely complex geometries in small batches while simultaneously being capable of handling the high-volume processing of simple geometries is a major challenge that many companies are currently facing. Also known as automation on demand, the Mobile Bending Cell is capable of overcoming these challenges—ensuring high flexibility as well as high quality and productivity.
This is achieved by means of the Mobile Bending Robot, which can be positioned in front of the press brake or detached to allow manual operation. Thanks to an intelligent and fully automated measuring system, the robot references itself in front of the press brake without requiring manual intervention. Laser sensors measure the precise position of the robot relative to the press brake and it is referenced accordingly. This allows the press brake to be converted from manual bending to fully automated bending in less than ten minutes. The relative position of the press brake to the Mobile Bending Robot is determined so accurately that the need for manual calibration is completely eliminated.
Once individual parts have been bent automatically, the process can be repeated without adjustments once the press brake and the Mobile Bending Robot have been connected. Depending on the requirements, the system can either be operated completely manually or fully automatically.
However, the “marriage” of press brake and Mobile Bending Robot is not the only critical factor for an efficient production process. The preparation of the parts that are to be bent is another process that incurs costs in every production run. For the automation on demand concept to really pay off, the process of programming the robot automation needs to be innovative and fast.
With the Mobile Bending Cell’s programming system called Robot Manager, the robot’s movements are programmed using algorithms that factor in comprehensive collision models for each relevant application. All that is required is the definition of basic positions and all the other movements are automatically defined by the software. This increases quality and reduces process idle time.
Automatic measurement of the press brake and bending automation system in combination with intelligent robot programming makes the Mobile Bending Cell the ideal solution for bending automation on demand.
To continue reading this article, head on over to our Ebook!
Check these articles out:
Powering Industry 4.0 With Factory Automation
TRUMPF Opens New Smart Factory In Ditzingen
Why You Need to Invest in Laser Cutting Technology
The Carefree Package For The Entry Into Bending
The Fully Automated Production Line
For other exclusive articles, visit www.equipment-news.com.
WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!
FOLLOW US ON: LinkedIn, Facebook, Twitter
Fully Automated Steel Production Facility
A look at how a steel company was able to press ahead with automation and enable unmanned operation in its facility.
