We are all used to seeing robots operating in a fixed location across many different industry sectors and applications. However, it is becoming increasingly common that you will also see a 6-axis robot moving on a linear track between machines or workstations. For example, instead of three robots each tending a machine at separate locations, a single robot on a track could potentially tend all three, saving money and increasing efficiency. Or, a single material-handling robot on a track could replace multiple robots with intermediate transfer locations.

The general perception however, is that these tracks are always floor mounted and being used to enhance a robot’s work envelope in just one plane. But as robot integrators turn to Güdel when they need to enhance the working range of their systems, they are finding that the flexibility of the Güdel TrackMotion range is opening up potential for some truly innovative concepts.

Depending upon the application, it may be that the robot needs to be situated overhead as opposed to floor level. Mount a 6-axis robot to a Güdel TMO (Track Motion Overhead) series linear track and its available work envelope increases significantly, opening up a host of opportunities for greater utilisation and providing automation specialists and system builders with a more flexible approach to cell design and concepts.

This overhead track configuration lends itself to many applications. For example, machine tending on CNC machine tools or injection moulding machines, where the gantry mounted robot can access the machines from above, opening up operator and maintenance access and easing guarding issues. Further benefits from this approach are potential savings in valuable floor space and the opportunity to use a single robot to serve multiple machines, thus delivering a highly flexible yet cost effective solution. Güdel’s overhead linear tracks can have the robot mounted in a ceiling or wall attitude to provide maximum flexibility, or they can simply lift the robot up in the air in a conventional position.

Another novel approach is to mount the Track-Motion unit vertically, and once again the robot can be mounted in whichever attitude best suits the application. Commonly, this vertical axis will be combined with a horizontal floor-mounted slide to give a huge, flexible working envelope, often to quite a small robot. It is quite normal to see a very large robot being used to carry a small payload because of reach problems. This idea of a multiple axis robot mover means that you can often use quite a small robot over a very large working area whilst maintaining high levels of repeatability.

A futuristic example, which demonstrates the ultimate flexibility available from Güdel linear track systems, can be seen at the ETH University in Zurich, where a new building, the ‘Arch-Tec-Lab’ has been opened, to explore the impact of digitisation and automation on the construction sector. The Robotic Fabrication Laboratory, or RFL, is a globally unique robotics laboratory, in which four 6-axis robots hang from a ceiling-mounted Güdel surface gantry. Together, the installation is based on 36 system axes that can be used to place objects with a precision of half a millimetre at any location in the 45x17x6m work envelope. The purpose of this laboratory is to develop the usage of complex wooden structures which require accuracy and repeatability to produce reliable load-bearing beams.

As manufacturers in all sectors seek to introduce automation to fill a skills gap, improve quality and productivity, or reduce manufacturing costs, it is certain that Güdel’s range of linear track systems will become an increasingly important part of many manufacturing automation systems.

Visit the Gudel website for more information

See all stories for Gudel

The vertical axis of this new gantry robot is a pivoting arm which really comes into its own in working environments where there are low ceilings or other height restrictions, such as operating under a beam. The PA-5 however, can still lift and transport the same loads as a conventional vertical axis.

A conventional vertical axis requires the same headspace above the main beam as the vertical stroke beneath it. By using the rigid and robust pivoting vertical axis we virtually eliminate the headspace requirement, and compared to the alternative for restricted spaces, a telescopic axis, we save more space and the payload is up to 25% greater. The PA-5 can also be fitted with an optional mobile overhead guard, which eliminates the need for overhead safety guards for the entire length of the horizontal axis.

The Güdel PA-5 gantry, in line with all other Güdel linear motion components, modules and systems, is ideally suited for use across a wide range of applications and industry sectors, such as machine tool loading, palletizing or press-loading. The key advantages of Güdel linear gantries, speed, accuracy and good use of floor space always remain.

Visit the Gudel website for more information

See all stories for Gudel

With an ever-increasing number of vehicles on the roads each year, the volume of tyres for OEM’s and the replacement markets continues to grow, which means it’s essential for manufacturers to optimise the way in which tyres and handled to make best use of precious manufacturing floor-space. Güdel Gantry Robot Systems have established themselves as an efficient and cost effective solution to tyre handling applications for a number of the Worlds’ leading brands. Güdel’s expertise in the sector spans some 15 years, both as a component supplier and as a supplier of complete handling systems. Projects completed by Güdel include transporting, storage, handling and palletising both green and finished tyres within plants in Europe, the US and Asia.

The capability of Gantry Robots to cover large areas whilst requiring only a minimum footprint is at the heart of their success in this sector. Typical installations will span widths of around 15 metres, and can cover distances up to 100 metres in length, enabling the efficient handling, sorting and storage of huge numbers of tyres.

The same Güdel Gantry Robot System concepts are used for completed wheel and tyre assemblies. In this application sets of 4 or 5 wheels, depending upon the type of spare wheel to be fitted to a vehicle, are sorted and stored. These are then picked as required to fulfil JIT and sequenced presentation to the vehicle assembly line.

Long gone are the days when a particular vehicle type would all have the same wheel and tyre combination. The increasing levels of personalisation available to buyers of new vehicles mean a wide range of wheel styles and tyre types must be readily available to match the requirements of individual vehicles. The capability of the Gantry Robot to span large areas, provides the maximum workspace available to store all of the different wheel and tyre combinations needed at any time.

As part of the complete solution for this sector, Güdel has also designed specialist gripper systems to handle tyres at their various stages of manufacture, including when in the green state.

Visit the Gudel website for more information

See all stories for Gudel

The UK is currently in the midst of some of the most significant political and economic changes seen in a generation. As we move towards what could be an uncertain future, there is however little doubt that manufacturing industry will play an increasingly important part in our economy and future prosperity. Against this background, it is clear that a dramatic increase in investment in robotics and automation will be essential if we are to remain competitive and achieve the productivity levels required to attain the growth needed to sustain our economy.

For a country with an impressive manufacturing heritage, the UK’s record when it comes to investment in manufacturing industry is quite depressing. There are regular articles in the news regarding our productivity compared to the rest of the world, and they don’t make comfortable reading. According to figures from the office of national statistics, amongst the G7 countries only Canada and Japan are less productive than the UK. Germany is at the top of the pile, being 26.7% more productive per man-hour worked than the UK. Even Italy with all of its current economic problems is 10.5% more productive than us. And why is this? In my view the principal reason is lack of investment.

Money for investment is at a historically low cost, and with the links that investing in automation brings about a corresponding improvement in productivity and hence market share, then the question becomes why on earth is the UK not doing this?

This can be illustrated very simply by looking at robot numbers per head of the working population. The International Federation of Robotics (IFR) recently published figures which show the UK near the foot of the table with just 71 robots per 10,000 employees in manufacturing industry. Our European cousins rate much higher, with France at 127, Spain at 150, Italy at 160 and Germany, which has more than four times that of the UK, boasting an impressive 301 robots per 10,000 employees in manufacturing industry.

The overall robot density in the large Western European economies is still currently ahead of China, who have 49 robots per 10,000 employees, but the robot population there continues to grow fast, boosted by the government’s aim to become one of the top technological nations. Their stated aim is to hit 150 robots per 10,000 employees by 2020. This is against the background that China’s economy was built up on the basis of low wages.

China’s approach is mirrored by Poland and the Czech Republic, also traditional low-cost economies, which are the two highest climbers in Europe in terms of robot installations. The Czech Republic’s robot density climbed 40% between 2010 and 2015.

Robots don’t cost jobs

The really interesting part of this though is the correlation between robots and jobs. In the US between 2010 and 2015, 80,000 new robots were installed, and in parallel with this the number of jobs in their automotive sector grew by 230,000. This same effect is seen in Germany where over the same time period their robot stock grew by 3% and their automotive workforce grew by 2.5%. The reasons for this linkage are quite straightforward. When you automate you bring down the overall cost of the goods you make and you improve their quality. You are therefore more competitive, so you sell more and you gain market share.

Of course, looking at robot statistics is only one indicator of the reason why we have relatively low productivity in the UK. Other reasons are more structural, such as education and training, transport infra-structure and the tax regime. It is very difficult for individual companies to do anything about these factors, but what they can do is invest in automation.

Money for investment is at a historically low cost, and with the links demonstrated above, that investing in automation brings about a corresponding improvement in productivity and hence market share, then the question becomes why on earth is the UK not doing this?

The UK has a historical reluctance to invest in manufacturing, with a government which seems to believe that the service economy is the key to all, but with Brexit on the horizon many of these jobs are threatened. Indeed we are already seeing several of the major international financial institutions setting up offices outside London in preparation for Brexit, so we need to replace these good quality jobs with others – why not in manufacturing?

This is something which is widely recognised across the whole of the UK robot and automation sector. As an industry, all of the recognised robot suppliers, machine builders, and system integrators, together with associations such as BARA and PPMA for example, continually campaign to raise the awareness of both the need for investment in automation and robotics, and the benefits that can be obtained by UK manufacturing industry.

Pledges from the Government in the latter part of 2016 to invest an extra £2 billion in science and technology research and development are obviously welcome, but these strategies are generally for the mid to long term. We already have the robot and automation technologies available today that can make a positive impact on productivity, performance and profitability in our manufacturing plants. What is needed in the short term is a change in the way investments and payback periods are calculated in the UK to encourage these vital automation projects.

Visit the Gudel website for more information

See all stories for Gudel