Metrology is the backbone of precision in manufacturing, yet its integration in automated robot cells has long been overlooked. While robots have revolutionised production processes, their setup and maintenance have paradoxically remained labour-intensive and prone to error. Renishaw is addressing this gap with a new approach.

The existing processes surrounding robot set-up and maintenance are largely manual. It’s a strange conundrum for an industry built on automation. Robotic automation cells are prone to inaccuracies over time due to wear and tear, environmental factors and complex operational demands. Without precise calibration and monitoring, these issues can lead to production errors, increased downtime and costly inefficiencies. At Renishaw, we decided to change that.

Renishaw’s approach for developing products for the industrial automation market was grounded in addressing these fundamental challenges. We focused on issues relating to the manual set-up, calibration and maintenance of robots, aiming to enhance operational accuracy and repeatability.

To meet the needs of the market, we decided to offer two options: a portable product toolkit and permanently installed in-process products.

The toolkit products can be taken from job to job to speed up robot commissioning and ongoing verification. They include the RCS L-90 ballbar, which improves robot system accuracy, reduces deployment time and monitors robot health. The technology works with the coordinating software package, the RSC Software Suite, to intuitively guide users through a range of tests and simple routines.

The RCS T-90 tri-ballbar is purchased as an add-on kit. This system uses a tripod configuration of three ballbars, which enables robot users to identify root causes of poor performance, with further comprehensive tests to capture critical robot information. Examples include remastering the joint offsets to calculated positions, running master-recovery routines and plotting 3D path performance.

Remastering joints is a good example of a crucial function of robotic testing – especially in high-precision, high-repetition tasks where robots are most commonly used. Enabling quick and accurate joint remastering allows manufacturers to swiftly correct any misalignment, eliminating the need for extensive manual adjustments or prolonged downtime. This ensures that robot performance remains consistent without disrupting production.

The RCS P-series of in-process products integrates a permanent Renishaw probing solution within a robot cell to apply in-process metrology. The RCS P-series uses probes and tool setters to enable cell auto-recovery, which minimises downtime and allows operations to resume at the touch of a button. Available in a variety of bundles, the RCS P-series enables users to customise their package to suit the needs of their robotic cell.

Development and history

Automation cells are designed to be operated with minimal intervention, but to truly run autonomously, a closed loop approach must be applied. This is the goal Renishaw set out to achieve.

It’s the application of our established and trusted technology that sets us apart from the competition. We have a long history of expertise in metrology and the automation of processes for physical automation. As such, we provide a holistic solution to widely recognised industrial automation problems. Our products offer a blend of portability and robustness that meets the high standards of precision and reliability expected by the industry.

In fact, the products complement our core manufacturing products, demonstrate the versatility of our approaches in related markets and showcase our commitment to innovation and quality.

Given our history of innovation and expertise in precision engineering, developing products for industrial automation was a natural fit. We’ve been using high levels of automation in our own manufacturing facilities for decades. We therefore have first-hand experience of the challenges faced by the sector. Historically, automation activities have required far less accuracy than high-precision manufacturing. However, the improvements that our RCS products are bringing to industrial automation cells are revealing new applications that could be automated successfully.

The market reception to this product line has been overwhelmingly positive. We’ve seen a keen interest in the capabilities that our products offer, particularly in improving manufacturing efficiencies, raising production quality and automatically recovering from crashes without reprogramming. Testament to our success is the feedback from key industry players who recognise the transformative impact of our solutions.

The future of metrology in automation

Looking to the future, we’re dedicated to driving product innovation by continually engaging with end-users and integrators, understanding their needs and developing solutions that address the evolving challenges of the sector. We’re committed to advancing our products through research, customer feedback and leveraging our cross-industry expertise.

In fact, we anticipate our product range to be at the forefront of innovation in the industrial automation space. We’re exploring new applications and technologies that will further enhance the capabilities of our products, ensuring that Renishaw remains a key player in driving the future of industrial automation.

Renishaw’s approach is transforming the role of metrology in robotic manufacturing cells, tackling long-standing challenges in an industry built on automation. By eliminating the manual steps in robot calibration and maintenance, we’re setting a new standard for precision, efficiency and reliability.

With a relentless drive for innovation and a commitment to solving industry problems, Renishaw isn’t just supporting the future of industrial automation – we’re shaping it.

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Organised by industrial robotics specialists FANUC UK, the WorldSkills UK competition is one of the most widely respected national robotics contests. The finalists had to design an integrated cell robot system to load and stack totes on a pallet ready for shipment. The totes had to be loaded with specific numbers of packages of different sizes. The project was more complex than in previous years, involving three stages – setting up the robot and cell, completing the basic task and attempting an extension task if time allowed. The decision to assign contenders more advanced tasks was in response to an increase in the number of applicants and overall ability.

“Morgan and Aled’s success underscores their advanced technical skills and the immense dedication and effort they have invested over the past year, setting an example for other aspiring engineers,” commented Simon Biggs, Early Careers Manager at Renishaw. “These apprentices are a great example of Renishaw’s commitment to fuelling innovation by attracting and nurturing young engineering talent. The pair demonstrated outstanding proficiency in programming robots to perform complex tasks, including creating a digital twin, showcasing their expertise in robotics and automation.”

Apprenticeships are core to Renishaw’s early careers programme. This year, the company welcomed 63 new apprentices alongside 100 graduates and 57 industrial placement students. Renishaw encourages applicants from diverse backgrounds with different skills and experience, with roles available in Gloucestershire and South Wales. Early-careers employees gain invaluable insight from industry-leading specialists, whilst working on real-life projects and products.

Both Aled and Morgan are mechanical engineering students at Bridgend College and are currently undertaking their apprenticeships at Renishaw’s manufacturing facility in Miskin, South Wales. They hope to pursue engineering careers at Renishaw after completing their programmes.

Aled commented: “I am proud to represent Renishaw at this world-leading competition. It’s great to work for a company that encourages young talent to go the extra mile and put their skills and creativity to the test.”

Morgan added: “My ambition is to get into programming in the future and this early-career experience has been a unique opportunity for me to prove my skills and determination.”

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Additive Automations is a Sheffield-based start up that creates robotic systems to automate additive manufacturing. After obtaining funding from UK and Canadian bodies, its founder and CEO, Robert Bush, collaborated with both Renishaw and the University of Sheffield Advanced Manufacturing Research Centre (AMRC). Since August 2019, Renishaw has been assisting Additive Automations’ progress by providing its industry leading AM expertise.

Renishaw provided four examples of AM builds, so the start-up could demonstrate its support structure removal system. The four AM parts were designed for medical, oil and gas, automotive and mechanical engineering applications. Testing its robotic system on parts already being used in industrial applications will help Additive Automations demonstrate the potential of its product.

The project, named Separation of Additive-Layer Supports by Automation (SALSA), aims to use robotics and deep learning to digitalise some of the few remaining manual processes left in AM. Cobots were chosen for their high payload-to-size ratio and integrated force sensors, which collect data to determine the geometry of AM parts. Software then analyses the data, using digital twin technology. The output is then used to determine where the support structures are so that they can be removed using an end-effector tool.

“Automating support removal and finishing in AM completely changes the economics when scaling up AM, and for the first time makes it feasible for manufacturers around the world to adopt this technology in rapid production,” explained Robert Bush. “The digitalisation of AM also comes with an increase in quality, traceability and repeatability. Given that on average almost two thirds of post-processing costs are from finishing and support structure removal, we believe automation can reduce costs by an average of 25 per cent per part.”

“Improvements in post-processing could bring AM to the forefront of new applications in medical and aerospace applications,” explained Bryan Austin, Director of AM Sales at Renishaw. “An automated manufacturing process could make AM adoption more appealing to manufacturers operating large volume production lines.”

Renishaw is a leading global manufacturer of metal additive manufacturing systems, and is at the forefront of AM development. The company has worked to innovate additive manufacturing technology and develop new applications in sectors as varied as aerospace, motorsports and dental care.

For further information on the latest advancements in additive manufacturing, visit http://renishaw.com/additive

BCH hosts a National Association of Epilepsy Centres (NAEC) accredited Level 4 Epilepsy Centre, and the team plans to begin integrating their newly installed neuromate into their Stereoelectroencephalography (SEEG) procedures. The neuromate’s role will be to assist in positioning the intracerebral electrodes which identify the epileptogenic zone. The robotic system integrates with BCH’s existing stereotactic neurosurgery infrastructure for reduced procedure times and enhanced surgical capabilities.

Dr Scellig Stone is the Director of Stereotactic and Functional Neurosurgery at BCH, as well as an Assistant Professor at Harvard University. On the installation of neuromate he commented: “The addition of the neuromate system to our workflow promises to significantly increase the efficiency of our stereotactic surgeries, lower the risk for human error in targeting, and complements other neurosurgical technologies that together allows us to stay at the cutting edge of paediatric neurosurgical therapies.”

The neuromate stereotactic robot is designed to provide a consistent, accurate and repeatable platform during a broad range of stereotactic neurosurgical procedures. Through accurate positioning of the neuromate’s robotic arm, neurosurgeons can be confident of reaching structures deep within the brain safely.

Dr Abed Hammoud, CEO of Renishaw Mayfield SA (Switzerland) adds, “We are excited and proud that Boston Children’s Hospital have chosen the neuromate to be an integral part of their workflow. Our service team will work closely with Dr Scellig Stone and his team at this world class institution to address their needs as they continue to provide the best care for their patients.”

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In the storyline, neurosurgeons use advanced MRI technology and Renishaw’s neuroinspire software to identify the region of the brain responsible for generating the OCD symptoms. A carbothane neuroguide guide tube kit is used to create tracts for the insertion of thin and flexible specialist electrodes. Powered by a battery pack implanted in the patient’s chest, the electrodes deliver a series of persistent electric impulses to stimulate the symptom-generating region of the brain. DBS can have remarkable therapeutic effects in the treatment of OCD, and other neuro-disorders such as Parkinson’s disease. To be effective, the electrical stimulation must be delivered at a high frequency, typically greater than 130 Hz.

The success of DBS depends on careful mapping and targeting of brain anatomy. Accurate positioning of electrodes is essential. The Renishaw range of products for stereotactic neurosurgery are designed to integrate into a comprehensive system for improved efficiency and safety at each stage of the DBS procedure, from planning through to verification and delivery.

Renishaw’s neuroinspire software provides neurosurgeons with an easy-to-use platform for target identification and trajectory planning. The software fuses MRI and CT datasets into a 3D volume, enabling neurosurgeons to explore the best available approach to the target, avoiding key anatomy and blood vessels.

Whilst the neurosurgeon remains in complete control of the procedure, neuromate can assist by providing a stable base and accurately aligning the surgical tools in accordance with the neurosurgeon’s pre-planned trajectory. The ergonomic functionality of the neuromate robot combined with state of the art pre- and intra-operative imaging technology can improve chances of accurate electrode placement.

The neuroguide electrode delivery system, designed for use in DBS, is a long-term implant which facilitates electrode implantation by acting as a conduit, preventing the electrode from bending off target. The neuroguide system includes a radio-opaque stylette which can be used for target verification prior to electrode implantation.

The patient undergoing surgery in Holby City is kept awake during the DBS procedure. Historically, this would have been necessary to allow the neurosurgeon to monitor the patient’s response to treatment. A typical DBS procedure lasts 6-8 hours, which can be grueling for both patient and neurosurgeon. The prospect of remaining awake has often acted as a bottle-neck on the number of patients receiving the benefit of this treatment.

However, improvements in surgical imaging and supporting technology, including the products from Renishaw described above, means that DBS is increasingly available as an asleep procedure. Increasing confidence in the ability of medical technology to support accurate delivery reduces the need for the patient to be conscious for verification, greatly reducing stress and improving the patient experience.

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Richard Selway and Irfan Malik, consultant neurosurgeons at King’s College Hospital, have already successfully used the systems for several stereoelectroencephalography (stereo EEG) cases for epilepsy, since the installation in January 2016.

Selway said: “We are delighted to be able to offer robot-assisted brain surgery to our patients at King’s. The increased precision and efficiency of the machine allows fantastic accuracy when targeting the most sensitive areas of the brain. It is likely to revolutionise certain aspects of surgery, particularly for children with severe epilepsy or in the surgery of brain tumours.”

Malik added, “In the short time we have been using the robot we have seen marked improvements in accuracy; something which is of course crucial in the field of brain surgery. This will allow safer surgery with quicker recovery for our patients.”

Stuart Campbell, clinical sales and development manager for Renishaw’s neurological products said, “We are very excited to have installed a neuromate system at one of the UK’s largest teaching hospitals with a focus on neurosciences. The neuromate system will contribute greatly to the epilepsy programme, and Renishaw looks forward to working with King’s College Hospital as it develops their procedures and services around the robot.”

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Martin Tisdall and Kristian Aquilina, consultant neurosurgeons at GOSH (pictured right) have already successfully used the systems for several Stereoelectroencephalography (stereo EEG) cases and stereotactic biopsies since the installation.

Tisdall, said, “The Renishaw neuromate is a fantastic tool for stereoEEG implantation. It has allowed us to place electrodes with submillimetric accuracy and this, in combination with the neuroinspire software gives great confidence to the surgeon even when targeting complex trajectories. The service and support we have received from Renishaw has been second to none.”

Aquilina, added, “Renishaw is a leading engineering company with a particular commitment to healthcare, especially for children and young people. Their numerous innovations have led to ground-breaking changes in deep brain stimulation, Parkinson’s disease and the direct delivery of chemotherapy into brain tumours. At Great Ormond Street Hospital the Renishaw neuromate robot has already led to significant improvements in the way we biopsy tumours in delicate regions of the brain, where submillimetric accuracy is vital.

“We look forward to a long-term productive collaboration with Renishaw for the benefit of children and young people, particularly those with currently incurable life threatening disease.”

Stuart Campbell, clinical sales and development manager of Renishaw, said, “The use of the Renishaw robot will contribute greatly towards the innovative procedures Great Ormond Street Hospital is developing for the treatment of epilepsy and neuro-oncology. Renishaw is very excited to be working with such a world class institution and pioneering neurosurgeons to develop better surgical procedures and solutions.”

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Pictured: Ashwini Sharan using neuromate at the Thomas Jefferson University Hospital

Ashwini Sharan, MD, professor and director of the Sidney Kimmel Medical College Department of Neurological Surgery and his colleague Dr Chengyuan Wu, consulting neurosurgeon have performed the first case using the neuromate robotic system for a Stereo-EEG implantation case in Epilepsy.

Dr Sharan said, “The newly acquired neuromate system will provide me and my team with a platform for a broad range of stereotactic neurosurgical procedures. We are pleased to have a neuromate at our center, as we believe that this is only the beginning of an exciting future for robotics in the neurosurgery operating room.”

Dr Abed Hammoud, CEO of Renishaw Mayfield SA said, “This installation confirms the trust of a leading US neurosurgical center in the neuromate system and in Renishaw. Our clinical and technical support teams will work closely with the neurosurgery team at Thomas Jefferson University Hospital, to ensure the seamless integration of the neuromate into their surgical workflow, thus aiding them to provide optimal outcomes for their patients.”

The neuromate stereotactic robot provides a platform for a broad range of functional neurosurgical procedures. neuromate has been in used in thousands of procedures. Surgeons around the world rely on:

• neuromate for electrode implantation procedures for deep brain stimulation (DBS)
• neuromate for stereoelectroencephalography (SEEG)
• neuromate for stereotactic applications in neuro-endscopy and biopsy
• neuromate for research applications

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Dr Giorgio Lo Russo, Director of the Centre said, “The neuromate system is an integral part of our surgical workflow for invasive recordings with Stereo EEG, indispensable for the diagnosis of MRI-negative epilepsy patient. We are pleased to be equipped with the latest technology available to the benefit of our patients.”

Mr Paul Skinner, Head of Operations and R&D at Renishaw’s Neurological Products Division added, “This upgrade installation confirms the trust of one of the leading neurosurgical centres in the neuromate system and in Renishaw. Niguarda Hospital is one of the key centres providing us with surgeon input for our software and hardware research and development. This type of collaboration with leading clinicians is an integral part of our strategy of developing solutions for the future.”

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The PhD student in charge of these studies will be surrounded by a multidisciplinary team (experts in biomechanics, robotics, image processing, and of course neurosurgeons). Professor Decq is also Head of the Department of Neurosurgery at Beaujon Hospital, Clichy, France where he routinely uses the neuromate for neuro-endoscopic procedures and biopsies. He is an internationally recognised expert in neuro-endoscopic procedures.

Adrian Gut, Global Head of Sales and Marketing for Renishaw mayfield said, “It is a great opportunity for us to have this partnership with Professor Decq and this prestigious laboratory to develop new applications for our neuromate system.”

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