CONTROL & AUTOMATION INCREASING CAPACITY
ICS ROBOTICS AND AUTOMATION LIMITED
Robotic Automation used in the fight against Covid-19
The Covid-19 pandemic has been tough for a lot of businesses . However , a number of companies have been busier than ever , as they rise to challenge of fighting the Covid-19 threat . Wesbart UK are one of these companies who have a 40-year heritage of expertise in designing and manufacturing aluminium and stainlesssteel sample storage systems for laboratories , hospitals , universities , and the pharmaceutical industry across the globe . With the global programme of Covid-19 vaccination their products have been in high demand .
During the first lockdown ICS Robotics and Automation Limited were approached by Wesbart UK who were looking for assistance to add robotic automation to their factory . With the main aims of increasing the capacity of the factory and maintain high levels of quality needed for the pharmaceutical industry .
Wesbart UK were looking to automate the tending and operation of two Bystronic press brakes being used to fold the extensive range of products needed for the Covid-19 vaccination programme such as freezer racks and trays .
Most brake press cells with robotic automation are designed to fold small steel parts , which are stacked within the brake press cell itself . This makes it easier for robots to operate but limits the usefulness of the automation itself . Due to the extensive range of parts being produced by Wesbart UK , the standard brake press ( with robotic automation ) solutions on the market were not capable of folding the full range of parts .
ICS Robotics & Automation Ltd were engaged to develop a custom solution capable of folding the complete range of Wesbart UK components . The current Wesbart UK CNC punching process meant that parts were lightly oiled and were not easely stacked . Therefore , an infeed and outfeed solution using conveyors and a vision system was developed to ensure sufficient buffering was achieved and parts were not damaged by avoiding the traditional mechanical chute in a pallet box .
ICS Robotics & Automation Ltd developed the interface between the Bystronic press brakes and the KUKA robots to allow for a full automatic control of the brake presses in a safety interlocked system . The system was designed such that one of the press brakes can be used as a manual operation while the remainder of the machine is utilised in full automatic mode . ICS Robotics & Automation Ltd provided the full Turnkey solution which included full training to cover robot programming , vision training and overall system operation . Full on site commissioning and support was also provided with remote support utilising the VPN connection to the system was also included to allow ICS Robotics and Automation Ltd to provide timely breakdown and support services .
The main Components used in the robotic automated brake press system were :
• Robots - 3 off KUKA KR10 R1100 with Ready to Pilot option and safe range monitoring .
• Vision System - Keyence XG-X2200 vison controller with 2Mp Monochrome vision cameras
• Pneumatics - SMC ZK2 Vacuum ejector
• Press Brakes - 2 off Bystronic Xpert 40
The investment made by Wesbart UK in this automation process has allowed them to continue to compete across Europe with the view of opening new markets in the US . For larger batch production , it also improves their quality and production costs .
Robotic automation has removed the monotonous task of folding thousands of the same component allowing staff members to focus on more challenging and involved bespoke products . It has allowed Wesbart UK to offer their products to the market with a reduced lead time due to increased production hours and increased efficiency whilst reducing waste caused by human error . Staff members will not develop repetitive strain injuries as a result of carrying out the same tasks for serval days . Staff members selected to programme the automation equipment also have the opportunity to increase their skill set .
Based on their positive experience with ICS Robotics and Automation Ltd , Wesbart UK are now looking at other areas in the manufacturing process that can be automated . There are plans to extend the conveyor or add a pick and place robot so the punched parts can be placed directly onto the conveyor ready to be folded , this removes the need to collect parts after punching and place them on the conveyor . There are also plans to review other processes within the company such as product assembly with the option of introducing future automation .
For further information , please visit www . ics-robotics . co . uk
44 PECM Issue 50