The six featured in this publication are pick and place; machine tending; packaging and palletizing; processing tasks – gluing, dispensing or welding; finishing tasks – polishing, grinding or deburring and finally, quality inspection.

In each case the white paper gives an overview of the application, explains how the robot handles the process and the common accessories required for the cobot to successfully complete the task.  How long it takes to programme the cobot is also calculated and each example is rounded off with a short description of the typical benefits achievable from cobot integration.

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When manufacturers also realise that offshoring also usually involves complex logistics, added shipping times and difficulties in reacting quickly and nimbly to changes in customer requirements, there are clear reasons why many companies are looking for new ways to reduce costs and increase productivity. And for many, automation using cost-effective, advanced robotics technologies is the answer.

In a new White Paper available for download, Universal Robots outlines some of the key ways collaborative robots are contributing to this trend. It considers the key drivers in the process and outlines some of the mechanisms involved in which cobots play a crucial role. Finally, the Paper sketches some of the ‘big picture’ opportunities already emerging from reshoring and how the use of cobots can serve as a catalyst in this process.

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The white paper aims to provide a solution to common spot welding issues such as shunting, variations of coating and sheet thickness, and weld force disparity. It also addresses the concept that inspection techniques need to be time intensive and unreliable.

Dave Halford, welding industry sector manager at Bosch Rexroth, who authored the report, said: “Adaptive welding remains a small proportion of the UK’s welding market, but its ability to improve the quality of welds and drive costs out of the manufacturing process, cannot be ignored.

“Traditional methods are prone to a variety of weld disturbances, and inspection techniques take up valuable time with mixed results. By taking an adaptive approach manufacturers benefit from real time control and monitoring, as well as improved consistency.”

Weld testing, in particular, is seen as an area where new technology will offer significant improvements, as Halford explained: “Current quality checking methods are problematic and rest on two methods, ultrasonic inspection and manually opening a proportion of completed welds. The first option requires a high level of operator training in order to get consistent results, while the second leads to scrapped parts. Real time monitoring through adaptive welding eradicates the need for these time intensive processes.”

Adapt and change – How adaptive control of resistance welding can cut production costs and improve product quality can be downloaded from https://www.boschrexroth.com/en/gb/trends-and-topics/ls4adaptivewelding

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Pictured right: Harmonic Drive’s SDH is a shorter gear component for use in robotics, addressing the trend for smaller, lighter rigs

“After reading a recent white paper from Denso Robotics concerning the costs of owning a small assembly robot I got to thinking about all the little things that affect cost,” he says. “When choosing a robot it’s important to consider the guidelines Denso outlines in its paper, but to also carefully look at the parts that make it tick.

“Beyond the initial cost of purchasing a small assembly robot, the costs of its maintenance and the energy it consumes can run on and on – especially if internal parts, such as gears, are sub-par.

“A machine using unsuitable gears can incur increased energy bills, increase the level of maintenance required, reduce accuracy creating increased waste, drive up production costs, and decrease lifespan. Reducing these costs and making robotics a more gainful investment is one of the key benefits of our ColbaltLine series of gears.”

Harmonic Drive Cobaltline gears are included, for example, on the KR Agilus robot from Kuka to deliver safe and reliable power transmission. According to Harmonic Drive, the Cobaltline series gears have 30% more torque capacity and lifetime increased by 40%, when compared to the HFUC technology. This has been achieved, says the company, by optimising the Flexspline and Circular Spline teeth and adapting the shape of the Wave generator.

In addition, Harmonic drive has introduced a shorter gear component for use in robotics, addressing the trend for smaller, lighter rigs. The new SHD drive has a hollow shaft incorporated into the centre of the unit with a diameter ranging from 11 to 40mm, allowing the feed-through of cabling, supply lines and other services.

I would advise anyone who is planning to buy a robot to request specific information from robotics manufacturers

Available in six sizes, from 14-40 with equivalent weights of 0.33 to 3.09kg, the SHD-2SH series units are available with a repeatable peak torque from 12 to 453Nm and reduction ratios of 50, 100 and 160:1. This enhanced power-to-weight ratio is complemented by a shorter Flexspline and heavy duty output bearings.

The SHD-2SH series has been specially adapted to incorporate heavy-duty cross roller output bearings to minimise the overall length. The bearing can withstand both high axial and radial forces as well as high tilting moments.

“I would advise anyone who is planning to buy a robot to request specific information from robotics manufacturers,” concludes Mackrell. “This not only helps ensure they get an accurate machine capable of performing to their needs, it also gives a more precise view of where long term costs may be incurred.”

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Nigel Dawson, product manager at Festo, says: “A Cartesian handling system may lose out on flexibility but it can be optimised for the application in hand. Importantly from a maintenance perspective, a Cartesian handling system can be assembled from standard parts. This makes a Cartesian handling system a lot easier to maintain. Parallel rod, Kinematic solutions can be much faster than a Cartesian handling system but there are working envelope and payload restrictions. There is no one size fits all approach, each should be considered on its merits.”

Entitled “Cartesian handling system – a technical comparison with conventional robots”, the whitepaper will help engineers and designers understand the advantages and disadvantages of the Cartesian handling system and other handling systems, so they can increase the productivity and efficiency of their processes.

An energy-efficient 2D and 3D Cartesian handling system can be engineered easily and efficiently to linear and rotational applications. A Cartesian handling system can also incorporate pneumatic, electric, servo-pneumatic or a combination of technologies: this means the Cartesian handling system can achieve optimum movement in terms of efficiency, dynamic response and function, enabling engineers to improve productivity.

The whitepaper on the comparison between the Cartesian handling system and other handling solutions is free to download from www.festo.co.uk/handling-whitepaper. And you can visit the Festo website for more information on its Cartesian handling system solutions.

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