The cobot picks and places parts using Sempre ’ s own low cost pneumatic dual gripping end effector and 3D printed gripping fingers to hold the part . The team also modified Hardwicke ’ s existing Rohm vices for automated actuation . The robot picks the parts from a pallet , opens the door of the CNC machine , unloads complete parts from the machine , cleans the vice , loads the next part and then closes the door . Parts are then measured using a coordinate measuring machine ( CMM ).
“ The system was quick to set up , flexible and viable — it went from van to operation in three hours . The Sempre Group also ensured that the system could operate safely around the team — the robot is able to detect humans in its path and execute a safe stop , removing the need to cage the system , which would take up a lot of space in the facility . The robot ran 24 hours a day , seven days a week and delivered the output we needed , meaning the team could work on our other CNC machines to produce other components .”
“ We installed Sempre Connect software to the system to very easily and quickly connect and control other systems within the process ,” explained Mike G John , head of engineering at The Sempre Group . “ In this case we integrated a Vertex 251 Optical CMM to inspect the components and ensure compliance . Any dimensional issues could then be flagged immediately and the machine tool program assessed for changes . This instant quality feedback allows a proactive approach to superior productivity and quality control .”
Sempre Connect is a simple software that eliminates the need for programmable logic controllers ( PLCs ) and integrates the inspection system with the automated process . After measuring , the software verifies the part , checking that it meets specifications , and feeds this information to the automation solution to place the part in the correct place . This PC based control software is simpler , cheaper and easier to use than an industrial PLC , which is often a costly investment for SMEs because it can take months to learn how to use and program the technology effectively .
SAVING TIME
The automated machine tending system had a 20-component capacity on each plate , a cycle time of three minutes 45 seconds and a takt time of four minutes 45 seconds . The Hardwicke team reported that the system saved around 52 hours of operator time that it could reallocate to other projects .
“ While some businesses view robots negatively , as they think that they will replace staff , this project showed the real value in technology ,” continued Foster . “ Robots take people away from laborious tasks and create roles that require highly skilled people . So now , we have an expert team that can work on different tasks while robots run all day , to meet demand for higher volumes .”
“ Our collaboration with Hardwicke proved the importance of investing in automation to unlock value — businesses can now use both staff and technology to their full potential to improve productivity ,” continued John . “ Now that we understand the value the system can add to the production floor , we can look to leverage the investment and ROI by developing and offering bolt-on applications . Manufacturers could use the system for applications such as post processing , including deburring or polishing , for packaging , including boxing or palletising , for assembly or for sorting . Manufacturers can simply reprogram the system in minutes , without the costs of introducing more equipment .”
“ This project was a one off for us — the small batches that we traditionally produce will not benefit from automation . However , as we start to see businesses look for more local suppliers , demand for higher volumes of parts will increase . As a result , we expect to see more high volume contracts , which we can now confidently accept without concerns about overhauling our production line . We ’ re confident that The Sempre Group can quickly and efficiently install the system , upscale our production and increase our flexibility to continue delivering high quality parts , no matter the batch size ,” concluded Foster .
The Sempre Group can help businesses of any size to automate their quality management processes and improve productivity . To find out what system could work well in your application , contact sales @ thesempregroup . com .
For further information , please visit www . thesempregroup . com
Issue 54 PECM 45