Furthermore, automatic tool changers can be implemented if the same welder is being used for different parts which cannot be handled by the same EOAT. The robot simply moves to the drop-off point for its current EOAT, releases it, moves to the required tooling and engages.
Enhanced Safety
Workplace accidents have a devastating impact, both on the individuals involved and the company. Many types of safety systems can protect operators from being injured by hazards present in machinery, but the most robust method: removing the operator from the hazard. By implementing robotics in the automation of RW applications, the operator need not access the machine during normal operation.
Robots can operate safely within a hard-guarded perimeter without the need for human interaction, and integrate into safety and e-stop systems. Safety solutions may be as simple as an e-stop button that stops the robot, and a safety door that only allows the robot to be manually moved at a safe speed for teaching. More-complex safety circuits only allow the robot to operate within safe zones while other areas are being accessed.
Ergonomics
Machine ergonomics go hand in hand with machine safety. Repetitive motions or loading and unloading of large, heavy or awkwardly shaped workpieces present ergonomic risks to any operator. Using robots for these tasks can reduce the risk of an employee developing a musculoskeletal disorder. And, with the reduced need for manual adjustments to be made at the machine, designing an ergonomic-friendly system becomes easier to achieve.
Automation Considerations
When considering automating an RW process, evaluate the following key factors to ensure an effective, scalable and cost-efficient solution.
Process complexity. Assess whether the process is repetitive and structured enough to be automated. Highly variable or intricate tasks may require more advanced robotics or automation systems, while simpler, repetitive tasks are easier to automate.
Cost and return on investment (ROI). Automation can be expensive upfront—calculate the ROI. Consider not just the cost of the equipment, but also costs for installation, maintenance and potential downtime during the transition. Weigh these against labor savings, increased productivity and reduced errors.
Volume and consistency. High-volume production processes benefit the most from automation, as it maximizes efficiency and throughput. Processes requiring consistency and precision also stand to gain from automation, as machines can maintain tighter tolerances than humans.
Scalability. The chosen automation solution should be scalable to accommodate future changes in production demand. Ensure that the system can be expanded or reconfigured should production volume increase or product designs change.
Integration with existing systems. Automation should integrate smoothly with the current production environment, including ERP software and manufacturing-execution systems, as well as upstream and downstream processes.
Workforce impact. Consider how automation will affect the workforce. Will workers need retraining to manage or maintain the automated systems? Also, examine potential job displacement and how the organization plans to address it.
Flexibility and customization needs. Processes that require frequent changes, such as product customization or short production runs, might require more adaptable automation such as collaborative robots or flexible manufacturing systems.
Maintenance and reliability. Automated systems require regular maintenance to prevent downtime. Consider long-term reliability and serviceability of the equipment, as well as access to technical support and spare parts.
Safety. Automation can improve safety by reducing human involvement in hazardous tasks. However, ensure that new safety protocols are in place for operating, programming and maintaining automated equipment.
Regulatory compliance. Ensure that the automation process complies with industry standards and government regulations, especially in highly regulated industries such as aerospace, medical devices and food production.
By carefully considering these factors, manufacturers can make informed decisions on automation as a fit for their processes, and how to implement it effectively. MF
See also: Taylor-Winfield Technologies, Inc.
Technologies: Pressroom Automation, Welding and Joining