“ABB’s contribution to Nobia’s new state-of-the-art factory clearly illustrates how we are helping companies unlock flexible automation to transform their business, supporting with unique global industry expertise and innovative, tailormade products,” said Andrea Cassoni, managing director for general industry at ABB Robotics. “Working with Nobia, our robotics solutions will enable fast mass-production of customised kitchens, meeting consumers’ increased demand for tailored and personalized product choices.”

The supply of ABB robots will enable Nobia to achieve its vision for more flexible and more automated manufacturing that’s capable of producing customised products at scale. By taking on the dull, dirty and sometimes dangerous tasks, the range of robots will enable Nobia’s workers to take on safer, more rewarding work.

The robots included are IRB 7600, ideal for heavy applications, IRB 4600, a general-purpose robot that increases production capacity and improves productivity, and IRB 6700, which ABB claims is the highest-performance robot in the 150–300-kilogram class, taking on average about 2.5 tons per day off the shoulders of an employee. The robots will enable the factory to produce customized cabinets with 75-80% higher efficiency (time) in comparison to non-automated processes.

Combining ABB’s technological leadership in automation with Nobia’s segment insights and knowledge of their customers’ needs, the relationship will lead to more flexible and digitalised manufacturing processes. Together, the companies strengthen the competence development within automation for the region around Jönköping. In the local area, ABB Robotics will support and educate Nobia’s existing and future employees as well as students at Jönköping University and neighbouring Linköping University. The training will be held in ABB Robotics’ recently opened training centre in Jönköping.

“We are very excited about this partnership with ABB,” said Jon Sintorn, CEO, Nobia. “We are building a future-proof, high-capacity factory that will support our leading position. It is a real game changer for the whole industry. The factory will manufacture customised, made-to-order kitchens at the highest speed and at the same time highest possible quality.

“The unique combination of technique solutions combined with our expertise will enable us to offer kitchens with leading design, and sustainability performance to customers in the Nordic region. To achieve this we will utilise ABB’s market leading technology for highly automated and flexible processes, and extensive logistics consolidation.”

Visit the ABB Robotics website for more information

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French kitchen manufacturer Schmidt has risen to the challenge of producing customer specific products using an innovative robotic machining cell for drilling, and assembly of kitchen furniture components. The cell is part of a production line used to manufacture complete kitchen units with a batch size of one.

Schmidt is recognised internationally as a quality supplier of kitchen products and has around 1,500 employees worldwide. The company has production facilities in Sélestat, Alsace, in France which is where the robotic machining cell is located. The robot processing cell was designed and built by the Zimmer Group, which delivered this production system as a turnkey supply.

At the heart of the system are five large ABB robots, connected by a flexible transport system within which the workpieces are clamped and moved, depending upon their size, using four freely programmable shuttles. The design and functionality of this recirculating shuttle system was recognised with a German Innovation Award in 2019. Operating on a cycle time of less than 2 seconds, furniture components have holes and grooves machined, plus fittings assembled, with all operations performed by the robots. A 2m-high side panel of a tall cabinet can be immediately followed by a shelf measuring just 15 x 20 centimetres, without any changeover or setup time.

“When we first discussed our plans for such a cell, we were told don’t do it, it can’t be done with sufficient precision using robots,” recalls Zimmer Group managing director Achim Gauß. “At first that was the case. We had to invest a lot in both hardware and software.”

The solution was derived through a compensation algorithm, developed in-house, which uses laser tracking measurement of the robots in the machining area. In addition, the individual furniture parts are clamped into the shuttles by a loading robot and then measured in terms of dimensions and position. This single set-up allows the parts to move along the various processing stations before finally being removed from the shuttles by the unloading robot. This ensures that there is no loss of accuracy due to un-clamping and re-clamping at different stations.

A special feature of this robotic solution, for which the Zimmer Group draws from its own pool of grippers and tool changers, among other things, is the drilling operation. This is performed by ABB industrial robots which process the parts with an accuracy of two tenths of a millimetre.

Achim Gauß continues: “Our customer Schmidt wanted a system that had 100% availability, if possible, where maintenance requirements did not have to lead to a complete machine shutdown. This is only possible with a modular system. In addition, there was the desire for flexibility, accuracy, future proofing, as well as a batch size of one production without predefined machining programs.”

Zimmer Group’s experts solved the availability problem by ensuring easy accessibility to all parts. Individual shuttles can be removed and replaced without the system coming to a complete standstill. In extreme cases, a ‘simple’ exchange of a complete processing robot is also possible.

Performance and flexibility at the highest level

In order to achieve the desired production output, the machining operations are automatically assigned between two machining robots and typical machining operations are combined in one drilling stroke. To achieve this, each of the machining robots carries a multifunctional head with 41 tools, in order to be able to perform all necessary machining operations without changing tools.

The desire for the greatest possible flexibility was achieved using special software – the so-called optimiser – which generates the machining program from the workpiece description in the customer’s central database when the system is loaded. This direct link between the control system to the higher-level manufacturing execution system achieves full production networking. In addition, Zimmer Group’s HMI provides intuitive operation and extended diagnostic options for the entire robot machining cell.

“In order to be able to reliably organize such a complex system during the design process, but also later when in operation, you need one hundred percent real-time simulation,” explains Achim Gauß. “Such a digital twin makes the system not only highly flexible but also extremely useful for work preparation and scheduling for the customer. We learned a lot in this project and have been able to transfer this know-how to all our components with the digital twin.”

With the help of the digital twin in the HIL system, the cell can be built virtually to be able to check the system performance and functionality even before installation. The Zimmer Group’s robotic machining cell both embraces and implements the principles of Industry 4.0.

Schmidt is delighted with the final result, as the cell offers considerable economic advantages in addition to extremely high system availability. For example, the use of industrial robots instead of traditional machine technology together with the simpler design, results in significantly lower investment costs. The re-circulating shuttles within the innovative transport system can be individually controlled in terms of speed, cycle time and positions, and can either be operated individually or in combination.

Considered over the entire life cycle of the system, the flexible robot concept also offers a high level of investment security, as the modular design enables subsequent expansion and future proofing with new processing modules.

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Door and security locks are precision parts with standard dimensions and components stipulated in DIN standards. Therefore, quality and precision were especially important deciding factors for Metal LS. In addition, the robots needed to achieve high productivity, assembling between 10 and 14 locks per minute. The company also needed a high level of flexibility from the solution and the possibility of retooling so that they could reuse the same system to produce different types of lock in the future.

Following a comparison of various manufacturers and products, Metal LS opted for a robot system from Delta. It was the only manufacturer to offer a complete solution including programmable logic controllers (PLC), a human-machine interface (HMI), servo systems and robotic arms with machine vision.

For implementation of this project, Metal LS and Delta collaborated to develop a custom workstation for assembly of the mechanical door lock components. The main part of the system comprises a rotation table, on which seven six-axis DRV90L7 articulated robots are installed. The robots are capable of extremely precise, quick movements and feature a hollow wrist that allows them to be easily combined with the correct tool for each production step.

The DOP-115MX HMI is used to visualise all processes and enables the user to select various receipts for different locks via a touch screen. It also displays system information and alerts or alarms. The AS300-series (AS324MT-A) PLC monitors the assembly line, controls the ASDA B2 servo drive and communicates with the servo drive on the rotating platform. Two DMV2000 Machine Vision image processing systems equipped with cameras are installed to localise components on the conveyor and send accurate signals to the robot allowing it to pick up and assemble the parts. The AC servo system comprising ASDA-A2 and ASDA-B2 drives as well as ECMA motors ensure that the robot arms are positioned precisely and that high productivity can be maintained.

A few adjustments to the parameter settings were sufficient to quickly overcome initial communication problems between the PLC, robot and the Machine Vision system. The careful preparation and system configuration carried out by the Delta team also ensured that all of the Delta industrial automation (IA) products were soon integrated into the production processes.

All stakeholders are extremely happy with the progress made in the project. Alongside the quality of the compact robotic system, METAL LS is particularly happy with the sound advice and customer service it has received from Delta. With many different production sites and teams throughout Europe, Delta is able to provide all of its customers with the support they need, when they need it.

The assembly system is still undergoing tests, but initial results are already showing improved productivity and performance.

Jason Wu, field application engineer at Delta Electronics, is very happy with the successful collaboration: “With our broad portfolio of IA products, we are able to offer our customers powerful full-range solutions from a single source. Our teams of experts will support clients in implementing the specific project requirements, no matter whether the clients are in the food, drinks, packaging, electronics or automotive industry.”

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“It is something no one else in our industry has ever done and has given us a competitive advantage in the marketplace,” said Richard Prudhoe, managing director of Fibreline, which is the largest independent cushion manufacturer in the UK. “We have now become the supplier of first choice because of our productivity, consistent quality, and our new capacity to do a large range and volume.”

The Keighley-based business, which was founded in 1982 and employs about 200 workers, supplies bespoke cushion fillings for up to 4,000 sofas every week. Fibreline is a high-volume, low-margin manufacturer with extremely short lead times.

Richard said: “We recognised some time ago that our processes had significant potential for improvement and have looked into automation in the past to remove labour from our production, but we quickly exhausted the obvious options. Commercial solutions were committed to large volumes of the same product and we just weren’t like that – we needed to find a solution to enable us to do small batches of a huge variety.”

Fibreline asked the University of Sheffield Advanced Manufacturing Research Centre (AMRC) to investigate whether two of its labour-intensive processes could be fully automated: the drilling of buttonholes in pieces of foam and the process of spraying adhesive glue to products on the assembly line. The AMRC is part of the High Value Manufacturing (HVM) Catapult network of research centres and the project was paid for in part using funds from the HVM Catapult as part of a commitment to working with small and medium-sized businesses.

Richard said they had made some progress themselves with a low-cost universal robot and an automatically generated drilling program, but it still required a robot programmer and an operator to set the parts in a fixed position.

“We started thinking that a vision inspection system could be used, but that took us into an area in which we were completely unfamiliar. That is why we approached the AMRC,” said Richard.

Robot Vision involves using a combination of camera hardware and computer algorithms to allow robots to process visual data from the real world. Cutting-edge research is done into the technology at the AMRC’s Factory 2050 in Sheffield, the UK’s first state-of-the-art digital factory entirely dedicated to conducting collaborative research into reconfigurable robotics, digitally assisted assembly and machining technologies.

“Fibreline had this concept of using a vision inspection system but they just didn’t know if it was feasible because there were so many unknowns: the success, the cost and the space it would take up. Doing this project allowed us to take all of the risk out of the potential investment,” said Dr Phil Yates, Project Manager at Factory 2050.

For the drilling process, Fibreline wanted to determine whether camera technology could remove the need for a fixed datum point, recognise different parts to be drilled and create a process that didn’t require a part to be in the exact same position each time. For the gluing process, the company wanted to use the camera recognition software to automate the generation of the spray path around the edges of the shape being glued.

“Fibreline sent a selection of their foam products to Factory 2050 and then we set up a demonstrator using one of our existing universal robots and a camera we had on site. The key was conducting trials with the camera to find the right specification, which we were able to do,” said Dr Yates.

The AMRC presented Fibreline with two documents. Richard said: “For the gluing process, the AMRC proved that certain elements of the project were feasible, but also identified issues that it could not solve. The second document was a full specification for a drilling cell using camera technology with a detailed description of how the process would work, the equipment required and the hardware we would need.

“Although the two documents had different conclusions, both were as valuable to us as each other. The first allowed us to confidently discount the technology for gluing and pursue another solution while the second document gave us the assurance we needed to go ahead with the investment for the installation.

“Simply, the AMRC de-risked the projects and saved us precious time and wasted money pursuing something that wasn’t viable. Additionally, the AMRC engineers helped us identify commercially available solutions to the manufacturing challenges we faced.”

Fibreline and the AMRC passed the report and drilling specification to robot integrator Olympus Technologies in Huddersfield, one of Fibreline’s existing suppliers. Director, Adam Swallow, said: “We used the output from a 21-megapixel Keyence camera, mounted above a turntable, to modify the Octopuz offline programming software drilling path, based on the actual position of the foam, giving Fibreline a fully optimised process.

“Crucially for us, the leading-edge project had been de-risked by the AMRC, who had largely proved the concept. This gave us the confidence to implement the project for Fibreline. Without that, we may have been reluctant to take on the project.”

Richard said the drilling cell has been in operation for more than a year and he is incredibly happy with the result. “There is no set up required from one product to another – the camera recognises the shape, it confirms the location and it confirms the program it needs to use,” said Richard. “It means we can move from one product very quickly to another, without any need to change parts, location or the setup of the tool.

“The AMRC brought a skillset we simply didn’t have. We had pushed our limits by using a universal robot and camera technology wasn’t something we had any experience of. The project has increased our capacity and improved our productivity, and we’re incredibly pleased with the result.”

Visit the AMRC website for more information

Traditional sanding automation solutions often require a background in robotics to implement and maintain. With the launch of OnRobot Sander, manufacturers now have access to a complete out-of-the-box sanding tool that’s easy to use with all major collaborative and lightweight industrial robots.

The complete Sander package incorporates everything OnRobot customers need to get their sanding application started quickly and easily: a plug-and-play sanding tool, a variety of standard sanding and polishing pads, easy-to-use programming software, an optional force/ torque sensor and a Grit Changer that enables automated switching between different sanding grits without operator intervention.

Taking useability a step further

Programming simple surface finishing applications on Sander is easy thanks to the intuitive built-in software. But OnRobot takes usability a step further with the addition of a “Save Position” button on the tool that allows users to set waypoints manually without using the robot’s teach pendant. The Sander software comes with different path planning options – handguide, shape and points, and allows users to adjust rotation speed, optimizing cycle time and consistency.

“OnRobot is committed to providing small and medium-size businesses with affordable, application-centered solutions that are easy to set up and maintain. OnRobot Sander is a versatile sanding tool that provides all the features and benefits our customers expect of automated sanding technology, but without all the hassle and cost traditionally associated with automated sanding tools,” says Enrico Krog Iversen, CEO of OnRobot.

OnRobot Sander supports flat, curved and uneven part geometries and comes with replaceable standard pads that can be used on a wide range of materials. Adding a force / torque sensor enables the sander to adapt to surface variations or part misalignment, while improving consistency and quality and reducing scrap rate. All of the advanced features of the OnRobot Sander are supported on Universal Robots cobots, but the tool is easily integrated with any major robot brand.

Significant cost savings compared to pneumatic sanders

Sander is a lightweight [1.2 kg (2.64lb), with pad] solution that combines the power of its brushless electric motor power (up to 10,000 RPM) with operating costs as little as 5% of that of pneumatic sanding systems. Traditional pneumatic sanding machines use external air compressors, which are very expensive and prone to leaks. Meanwhile, Sander’s brushless electric motor is durable and reliable with a lifespan equal to or greater than that of competing pneumatic systems.

“OnRobot is committed to democratizing automation, product by product and application by application, by making ready-to-go solutions available to companies that are completely new to automation. We take the cost and complexity associated with automation away, leaving our customers with the all-important functionality they need to get the work done,” explains Iversen.

Sander provides safer work environment

Sanding is often dirty and dangerous work that carries a range of potential health risks for workers, from the debilitating ‘white-finger syndrome’ caused by high vibration hand tools to lung damage caused by particulate matter. OnRobot Sander eliminates these risks and uses 3M clean sandpaper discs, which allow more dust to be extracted, thereby ensuring a safer environment for workers compared to competing systems.

“At OnRobot we’re seeing increased interest from companies that are completely new to robotics but are looking for ways to supplement existing labor through automation. These companies are looking for simple, user-friendly solutions, like OnRobot Sander, that can be easily deployed on a wide variety of tasks within each application domain,” says the OnRobot CEO.

Visit the OnRobot website for more information

The investment in automation represents the latest phase of the company’s high-tech design and manufacturing system, which has been developed by managing director Nicholas Showan.

Nicholas, an experienced engineer, who established the award-winning business in Barham in 1990, sought the expertise of Halesowen-based KUKA Automation + Robotics to help him shape a solution that complemented his lean manufacturing philosophy. “While I approached other robotics companies with my plans, KUKA was the most keen to discuss my ideas. Everyone involved in the project has been very helpful,” he commented.

The factory already boasts an array of automated machinery that is linked to a sophisticated online product design system devised by Nicholas to create an efficient, low-cost production operation from order placement to despatch.

“Jali has one of the highest productivity to staff ratios in the industry. I believe there’s more ground to be made by using automation instead of decades-old manufacturing methods,” said Nicholas. He plans to invest in additional automation solutions in the future, which may include a pick-and-place robotic application for a panel location racking system.

Visit the KUKA website for more information.

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The Decorative Panels Group (DPG) is Britain’s largest paper foil laminator supplying laminated board and furniture panels throughout Europe. Already using automated systems to cut panels to size, DPG had been investigating the use of robots for some time when two FANUC Robotics M710i robots became available to them through a company acquisition.

The robots are being used to load and unload Panels up to 3m in length into a Laminate edging machine. Panels, which can weigh up to 18.2kg are picked up by a robot at the input end using a vacuum gripper and placed onto a feeder which automatically takes the panel into the edging machine. A sensor in the gripper identifies stack height and the panel is delivered to within 5mm of the feeder table before being released. The process is reversed at the output end of the process.

Before the robot system was installed the process was manually loaded and unloaded usingthree operators per shift. The system is now operated by one operator who feeds stacks into and removes stacks from the system. Malcolm Forward, Managing Director, Decorative Panels, explains: “Its traditional to use portal frame or gantry type handling units in our industry but the space taken up by them is very prohibitive. The robots we’ve installed are ideal for confined space which in our case is at a premium. In addition by installing the robots we immediately remove the need for manual handling of heavy components and halve the labour requirement.”

As the robots were previously used for a different purpose, DPG were uncertain of their suitability. FANUC Robotics UK were contacted to make a thorough assessment of the requirement and to refurbish the two FANUC Robotics M710 robots.

Malcolm Forward explains: “Having these robots available made this a fantastic opportunity for us to try out robots – we didn’t know if they were suitable and FANUC personnel were very good. They carried out a site survey and undertook trials at their Coventry facility. This gave us all the confidence we needed to proceed with FANUC Robotics to refurbish the robots and to engineer the system.

“In summary the key benefits we have gained are saving space over traditional dedicated automated machines, saving labour costs and being able to adapt automation to an existing piece of machinery. So successful has the project been that we are now looking at the installation of additional robots.”

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