Fundamentals of Robotics

Bob Rochelle
Food & Packaging Industry Specialist
Stäubli Robotics

The Business Case for Robotics and Automation Dollars

Robots and the Robotics Industry
Robot and System Technology
Applications

1
 Robotics = Flexible Automation
Robots are integral to Lean manufacturing
 Manual  Hard Automation  Flexible Automation
 Fast product change
 High Volume  Quick product change
 Breaks
 Monotonous tasks  Requires Set-up time  Programmable
 Health Claims  More maintenance  Repeatable
 Labor Issues  Air Cylinders / actuators  Changeable Cell configuration
 Training  Rigid conveyors / fixtures  Responds to Part Changes

Robot Definitions

 Dictionary
 “An automatic apparatus or device that performs functions
normally ascribed to a human or a machine in the form of a
human.”
 Robotic Industries Association (RIA)
 “A reprogrammable multifunctional manipulator designed to
move materials, parts, tools or specialized devices through
various programmed motions for the performance of a
variety of tasks.”
 Robota
 Czech word for “forced labor” or “serf”

2
 Why Automate – reasons to spend

 Top Five Reasons for Automating a Process

 Need to reduce direct labor / Can’t get people to do the job
 Need to increase quality
 Difficult to do the job manually
 Need to increase production, meet specifications or provide flexibility
 Hazardous to personnel

Buy a Robot and Save America

 Article in Forbes Magazine “Buy a Robot and Save America”

 Average wage for an unskilled worker is $15 - $20 per hour plus benefits
 Average UAW wage for unskilled trades is $30 - $35 per hour plus benefits
 Average wage for similar labor in China is $3 per hour plus benefits(?).
 Offshore Manufacturing Risks and Issues

 Higher transportation costs and more problems

 Longer delivery times
 Quality problems
 International concerns like terrorism
 Loss of real-time control of manufacturing
 Loss of ability to make quick product or process changes
 Loss of closeness to your market and your end-customers
 A robot works 24 / 7 / 365 without breaks, benefits and legacy costs etc…..

3
 Buy a Robot and Save America

 2 shifts per day material handling for 20 years (80,000 hours)

 30 Kg Size – 5.4 kVA rating
 Electric rates 0.11 KwH = 0.594 cents per hour

 Maintenance Costs for 80,000 hours

 10,000 hour Lubrication – Lube 6 times
 Year 3 about $500 in lubrication costs
 Year 6 another $500 in Lubrication costs
 Year 9 another $500 in Lubrication costs

 8 – 10 Years expect some form of unscheduled maintenance

 $5,000 from typical Service Life Cycle Costs

 Well after 10 years refurbishment may be required

 Typical cost for full refurbishment - $10,000

Do The Math

 2 shifts / day for 20 Years

 Rebuild once in 20 years…….…….$10,000
 Maintenance for 20 years…….……$13,000
 Lubrication………………..$3,000
 Unscheduled repairs…..$10,000
 Power 0.59 x 80,000 hours…….…..$47,200
 Total ………………………….…….… $70,200

 OR do it Manually.
 80,000 hours x $30.00…….…… $2,400,000

Savings……………………...…… $2,329,800

4
 Buy a Robot and Save America
 Back to the article in Forbes Magazine “Buy a Robot and Save America”
 Average wage for an unskilled worker is $15 - $20 per hour plus benefits
 Average UAW wage for unskilled trades is $30 - $35 per hour plus benefits
 Average wage for similar labor in China is $3 per hour plus benefits(?).
 Average wage for a robot is under $1 per hour with no benefits.

THIS IS THE BUSINESS CASE FOR ROBOTICS!

Justification
Press Line - Manual Process

 Maximum Throughput
 53 seconds total cycle time
 Per press net yield of 68 pieces per hour
 One operator per press / shift – 3 shifts / day
 Six presses in operation = 7 Operators / Shift
 Labor rate of $12.00 per man-hour = $15.00 burdened
 $105 per hour
 Labor Cost per part = $1.54
 Yearly labor cost = $655,200

Part Flow
P P P P P P P

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 Press Line Justification
Press Line - Robotic Process
 Maximum Throughput
 10 seconds total cycle time
 Per press net yield of 360 pieces per hour
 One to one and half operators for entire line
 Six presses in operation = 1.5 Operators / Shift
 Labor rate of $12.00 per man-hour = $15.00 burdened
 $22.5 per hour
 Labor Cost per part - $0.63
 Yearly labor cost = $140,400

P
Part Flow
R R R R R R R

Complete Analysis

 Direct labor reduction

 reallocation of 5.5 operators per shift
 Direct labor savings of $518,800 per year
 81% throughput improvement
 53 seconds versus 10 seconds
 41% reduction in direct labor cost per piece
 $0.63 versus $1.54

Total investment for automating six presses: $1,050,000

Total direct labor savings: $518,800
Payback period (from direct labor alone): 24 months
Increased press capacity of: 81%
Part Cost Savings $0.91

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 The Green Sand Casting Process

 Green Sand Casting Process

 Create the mold
 mixture of sand, clay and moisture

 simple materials

 materials can be reused or regenerated

 low cost materials

 Pour molten metal into the molds

 Remove the parts
 Machining or clean up is required
 Green Sand Cast Parts
 Require surface finish
 Lowest cost casting process
 Labor intensive process
 Automated mold creating
 Hand Pouring
 Manual parts removal

Robotic Pouring
 Customer’s Results
 Four times the manual capacity
 Impeded by peripheral equipment
 One part every 30 seconds
 Reduced labor by three per shift
 Energy reduction
 automatic furnace lid closure provides insulation
 Operator Safety is vastly improved
 Reduced material use
 same quantity for every part
 Parts consistency is 100%
 repeatable process
 Increased Parts Quality
 metal heat more consistent
 pour efficiency

7
 Typical Performance

 2 - JS10 - Kg Robots
 First Installed in 1991
 Ran 5 second cycle time 3 shifts / day until 2003
 Re Installed in 2005 (75% capacity)
 Ran 10 second cycle time 3 shifts / day
 Both retired in 2008 due to line reconfiguration

 2 - JS10 - 10 Kg Robots
 First installed in 1992
 Ran 5 second cycle time 3 shifts / day until 2005
 Reinstalled in late 2005 (75% capacity)
 Ran 10 second cycle time 3 shifts / day
 One retired late 2008 due to wiring harness failure
 Second one is retired 2009

 3 FS10E - 10 Kg Robots
 First Installed in 2008
 Replacement for the JS10’s
 Run a 4 second cycle time
 Almost 20,000,000 cycles to date
 Over 25,000 hours

The Business Case for Robotics and Automation Dollars

Robots and the Robotics Industry
Robot and System Technology
Applications

8
 Industrial Robotics History
 History
 1956 - Unimation

 George Devol & Joseph Engleberger met

 First Working Model late 1956
 1961
 Patented
 First Installation - GM Lordstown, OH
 Die Cast Part Extractor
 Unimate Robot
 First Industrial Robot
 4000# Arm
 Step by Step Commands stored on a magnetic drum
 Hydraulic Actuators
 $100,000 Plus Price
 Original Model
 In Smithsonian Institute
 Hundreds still in operation today

Robot Industry - 2013

 Globally
 Over 850,000 at work today
 Over 100,000 sold per year
 $5,000,000,000 - robots
 $15,000,000,000 - systems
 North America
 Over 230,000 installed
 Growth rate as high as 20% yearly
 2008 / 2009

 2013 Setting new records

 Largest Users
 Automotive - 47%
 Electronic -15%
 Major Applications
 Material Handling - 39%
 Welding - 30%
 Assembly - 8%

Only about 10% of the US companies that could benefit from robots have installed any so for

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 Robotics Industry Players

 Robot Manufacturers
 Manufactures the robot
 Provides robot training, maintenance and service
 System Integrator [System Builder]
 Integrate the robot into a system to perform a specified task
 Independent business, industry specific, allegiance to robot manufacturer
 Has knowledge of End User’s business
 Provides system components, installation, training, service and support
 Design and build the robot based system
 Purchases robot and all peripheral equipment
 Designs and builds systems, writes and maintains programs
 Trained on entire cell / provides training on system
 End Users
 Uses the robotic based system in production or processing
 Knows what is required to accomplish tasks
 Ultimate user - needs training, service, maintenance, spare parts

Robot Manufacturers Today

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 Worldwide Distribution

Japan
#1
Americas
#2

 Industry Revenue - 1st Half 2013

 $715,000,000
 Robot Numbers
 Total orders – 11,308
 Double Digit Growth
 Semiconductors
 Food & Consumer Goods
 Life Sciences

Traditional Applications defined by the RIA

 Spot Welding
 Arc Welding
 Coating & Dispensing
 Less than 10 pounds

 Greater than 10 pounds

 Assembly
 Less than 10 pounds

 Greater than 10 pounds

 Material Handling
 Packaging / Palletizing

 Machine Tending

 Body Shop

 Other Material Handling

 Material Removal
 Inspection
Defined by Robotics Industry Association
www.robotics.org

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 General Terminology

 Work Envelope, Work Space or Reach

 Range of Motion (mm)
 The set of points representing the maximum extent or reach
of the robot hand or working tool in all directions. Also
referred to as the working envelope or robot operating
envelope.
 Payload
 Weight carrying capacity (Kg)
 The maximum total weight that can be applied to the end of
the robot arm without a sacrifice of any of the applicable
published specifications of the robot.
 Cycle Time or Speed
 Execution time for one task
 Additional Specs
 Torque / Inertia

The Axes – Degrees of Freedom

 Degrees of Freedom - Axes

 One of a limited number of ways in which a
robot joint may move.
 Joint 1 - Base Rotation
 Joint 2 - Rotation of the lower arm
 Joint 3 - Rotation the upper arm
 Joint 4 - Swivel of the upper arm
 Joint 5 - Bend of the wrist
 Joint 6 - Rotation of tool mounting plate

 Joint 7 - ??? – External Axes

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 Repeatability

 Repeatability
 Ability of the robot to return to a preprogrammed position.
 Closeness of agreement of repeated position movements under the
same conditions to the same location.

Assume repeatability to be +/- 0.004”

Robot can position

• • anywhere within the
• 0.008” diameter circle
• • and still fall within its
repeatability specification.
•

0.008”

Typical Specifications

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External Axes / Coordinated Motion

Axis 10 and 11 – Part Spinners

Axis 7 - Turntable

Axis 8 and 9 – Sky Hooks

Axis 1 to 6 - Robot

Common Industrial Robots

 Cartesian / Gantry
 SCARA
 Telescopic
 Delta Class
 Fast Picker
 Snakes
 Paint Specific
 Articulated
 AGV
 Modular

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 Cartesian / Gantry Robots

 Four Plus Axes

 Simple Motions
 Linear X, Y, Z
 Tool Rotation
 Components
 Base / Superstructure
 Arm / Runway
 Telescope / Carriage
 Controls

SCARA Robots

 Four Degrees of Freedom

 Advanced Control
 One Linear Axis and Multiple Rotary Axes
 Motions
 Rotational
 Linear Z Axis
 Highly Accurate
 ± 0.01 mm
 Fast and Vibration Free
 Adept Cycle: 0.30 – 0.35 seconds

300 mm

25 mm

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 Telescopic Robots

 Usually exclusive to Semi Conductor Applications

 3, 4 and 5 axis designs
 Clean Room applications
 Specific to Application
 Wafer Handling
 Flat Panel Screens – larger robots

“Delta” Class Robots

 3 Axes – Tripod / 4th is optional spin

 Very stiff
 Sorting and Picking
 Higher level vision required
 Conveyor Tracking function
 Low Payloads
 Pick and Place / Sorting

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 Fast Picker Technology

 High Speed Pick and Place

 200 Picks per minute
 Highly Accurate
 Very stiff
 Sorting and Picking
 Vision is typically required
 Conveyor Tracking function
 Low payload

“Snake” Robots

 Multiple Axes
 Stack of Servo Motors
 Versatile
 Slim Shape
 Advanced Freedom of Movement
 Uncommon outside of Automotive applications

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 Articulated Robots

 4, 5 or 6 Axis Designs
 Rotational Motions
 Most Common / Most Flexible
 3 Kg to 1000 Kg Payload

Paint Robots

 6 Axis Articulated
 Designed for Intrinsically Safe Environment
 Hazardous Areas
 Different Wrists
 Different Motion and Movement
 Specific to Paint

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 AGV’s

 Automated Guided Vehicle

 Floor Markers
 Vision or Lasers
 Material Movement

Modular Robots

 System with a combination of robot types

 Multiple Axes

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 Specialty Industrial Robots
Modifications to the base design

 Clean Room
 Machining
 Food Grade
 Wash Down
 Sterile
 Stainless Steel

New Applications and Markets

 Service Industry
 Food Service – RoboBar
 Care for the Elderly
 Emergency Service - Humanoids
 Medical and Pharmaceutical Industries
 Prescription Dispensers
 Hair Restoration
 Surgery System or Doctor Guidance
 Prosthetics Research and Design
 Steel Industry
 Food and Beverage
 Entertainment
 Warehousing

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 Beyond Industrial Robots?

The Business Case for Robotics and Automation Dollars

Robots and the Robotics Industry
Robot and System Technology
Applications

21
 Robot Components
Arm and Controller

Robot Arm or Manipulator

Wrist
Joints 4, 5 & 6 Motors

Counter Balance

Tool Mounting

Joints 1, 2 & 3 Motors

Arms

Base Floor Anchors

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 Drive System

 Design
 Belt or Direct Drive
 Components
 Brushless AC Servomotors
 Absolute Encoders / Resolvers
 Gears
 Couplings
 Timing Belts
 Drives
 Castings
 Maintenance
 None
 Lubrication

15 Minute Mean Time to Repair

Robot Installation and Mounting

 Installation
 Floor, Ceiling or Wall
 Direct to Floor or use a Riser
 Common Base for Systems
 Proper Fasteners / No Casters
 Tracks

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 Robot Environment

 Typical Environmental Specifications

 IP54 / 65 / 67 Standard
 Ambient Temperature: 0 – 52 oC
 Relative Humidity: 35% - 85% Non Condensing
 Vibration: less than 0.5 G
 Optional
 Clean Room
 Wash Down
 Freezer
 Sterile
 Intrinsically Safe / Hazardous Duty Units
 Typically for Spray Painting
 Explosion Proof Applications

Outside Typical Environmental Specs?

 Protection is required
 Covers

 Basic drapes for dirt protection

 Water resistance
 Cooled / Heated
 Acid Resistant
 Air Purged
 Other Protection
 Heat Shields
 Water Cooling
 Air Purged

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 Robot Controllers

 Robot Components
 Controller
 Teach Pendant
 Multi Controllers
 System Control
 PLC
 PC

Controller

 Design
 Houses Servo Amplifiers
 Houses Signal Amplifiers
 Houses Power Blocks
 Houses Programmable Controller
 Teach Pendant connects to the Controller
 Functions
 Robot Motion - Drives motors
 Coordinates all axes to control the Tool Center Point
 Controls I/O
 Digital
 Analog in / out
 Fieldbus
 Communicates with production system
 Modifies tasks per input or instruction
 Networks
 Collects Data
 Maintenance Monitoring

25
 Typical Controller Components
Teach Pendant

Disconnect

Operator Panel
Motor Control Center
PC Board Rack

Power Block for

Additional Axes
Memory / AC Power

Power Block for

Axes 1 thru 6
Transformer

15 Minute Mean Time to Repair

The Operator’s Panel

 The Operator’s Panel

 Apply motor power
 Cycle start programs
 Hold or stop programs
 Select modes of operation
 Reset errors
 Determine motor power status
 Determine error status
 E – Stop
 Working Mode Box
 Provides functions when the
controller is rack mounted

Break release switches are

used to manually release the
axes brakes with motor power
OFF.

26
 Teach Pendant

LCD Screen

E - Stop
 Design
Teach Lock
 Hand Held
 LCD Display
 Hard keys for Functions / Keyboard
 Functions
 Communicates with Controller
 Dead man Switches
Axes Keys  E - Stop
 User’s Interface to the Controller
 Monitor
 Teaching / Programming
 Operator’s System Interface Possibility
Alpha Numeric Keypad
Cursor Keys

Three position enabling device – Deadman Switch

located on the back

Programming
 Programming
 Developing the set of instructions that causes the
robot to execute a specific task. Can be performed
on-line or off-line.
 Teaching
 To move a robot through a series of points to be
stored in memory for the robot to perform its
intended task. Teaching is typically performed on-
line by means of a teach pendant.

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 Teaching / Programming Methods

 Teach Pendant
Teach Pendant Programming
 Programmer holds the teach pendant
 Manually teaches the robot
 Off Line Programming
 Program written remotely
 Higher level language
 Loaded into Robot Controller
 Touch up required
 No additional hardware is needed.
 Program Storage
 USB
 Other media
 Check Programs
 Slow speed operation

PC Programming

Robot System Software

 Simulation and Off Line Packages
 Graphical / GUI Overlay
 Soft Absorber
 Cooperative Motion
 Application Specific
 Palletizing
 Welding
 Dispensing
 Tracking
 Tending
 Paint
 Operator Interface
 Maintenance Log
 Line Balancing
 Help Function or Users Manuals
 Customizable

28
 Basic Robot Motion Teaching
 Define Tool Center Point
 Motion Instruction
 Defines a target position
 Interpolation Instruction
 Defines how to get to the position
 Joint Move - Robot articulates any axis to accomplish the move
 Linear Move - Maintains the tool in the orientation specified
 Circular Move - Three points and a radius to scribe a circle
 Speed
 Expressed in percent of full speed or a software set maximum speed
 Termination Instruction
 Expressed as a number [1 - 9] most to least accurate.
 Defines approach to the target position
 Additional Programming Activities
 Actions to be complete before moving to the next target position
 I / O switching
 Data acquisition

The Business Case for Robotics and Automation Dollars

Robots and the Robotics Industry
Robot and System Technology
Applications

29
 General Thoughts

 Robots are a Mature Product

 Pre-engineered / production devices
 Various models to choose from
 Very little customization at the robot level
 Repeatable
 Must have methods to deal with random events
 Programmability provides the flexibility
 Systems
 Some are Mature Products
 Building blocks for designs
 Many are Custom Designs

Industrial Robot Systems Components

 System Components
 Robot and Controller
 Arm Dressing and Risers
 End of Arm Tooling
 Parts Fixtures or Locators
 Interfaces
 Pneumatics
 Sensors
 Electrical Components
 Cables
 Peripheral Equipment
 Varies by application
 PLC or External Control
 Communication via Network or Discrete I/O
 Safety Components
 Fence, Gates, Interlocks, Light Curtains, Barriers, Awareness Beacons

The robot arm is only part of your robotic solution. End of arm tooling, industrial fieldbus systems, simulation and
software are among the issues critical to the success of your robotic system.

30
 Industrial Robot Systems Components
Arm Dressing

Robot

Tooling

Robot Riser

System Controller

Robot Controller

Safety Fence

System Development Process

 Recognize the need
 Determine that Robotics are an Applicable solution
 Identify the System Specifications
 What do you want to do?
 Existing Process, Reach, Payload, Speed, Operator Involvement, QC Issues,
Interface with Production System, Technological Capability of User
 Who is going to Integrate the system?
 End user, Integrator, Robot Manufacturer, Combination
 System Design and Build
 Preliminary Layouts and Design Proposal
 Space Required, Parts Movement, Tooling, Safety Concerns, I/O, Interfaces and
Communication, Operator Involvement
 Simulations / Cycle Time Study / Verification Tests
 Build, Test and Run Off the system prior to shipment
 System Start Up and Commissioning
 Installation, Start-up and Customer Acceptance
 Continuous Improvement

Involve all parties that will interface with the system in the development process to
assure acceptance when the system arrives in your facility

31
 Selecting a Systems Integrator
 Determine if the Integrator has experience in your industry
 Transferable knowledge
 Evaluate the Integrator’s background and capabilities
 Full Service
 Commercial Issues
 Check references
 The Integrator’s
 Robot Manufacturers
 Prepare for disaster
 What happens?
 After sale maintenance
 Integrator
 Robot manufacturer
 Cost
 Is the lowest bid the best?

Tooling / End Effectors / E.O.A.T

 The tool attached to the robot arm that actually performs the work.
 Vacuum Cups
 Grippers
 Spatulas / Fingers
 Spray Nozzles
 Dispensers
 Buffing Wheels
 Machine Tools
 Water Jets
 Welding Torches
 Resistance Welding Guns
 Saws
 Laser Cutters
 Ladles

Adds to the Work Envelope

Adds to the Payload / Torque / Inertia

32
 End of Arm Tooling Considerations
 Tooling Vendors
 Purchased Component
 Design Considerations
 “Building Blocks”
 Repeatable and Positive
 Include Sensors
 Part locators / verification of action / QC
 Environmental Considerations
 Tool Changers
 Manual
 Quick change
 Automatic

Arm Dressing / Cable Management

33
Part Fixture Considerations

 Tooling Vendors
 Purchased Components
 Design Considerations
 Repeatable and Positive
 Sensors
 Part locators / verification of action / QC
 Environmental Considerations
 No Parts Fixture?
 Can Locate – sensors or vision
 Fixture less system design
 Cooperative motion

Vision Systems
 Peripheral Equipment
 Camera
 Camera Controller
 Light Source
 Calibration Check Means
 Robot Components
 Robot and Controller
 Interface to Camera Controller
 Software
 Applications
 Part Location
 Robot Guidance
 Inspection
 Real Time Feedback

34
 Vision System Applications

Robot Cell Safety

 Responsibility
 Robot Manufacturer
 Integrator / System Builder / Installer
 User
 Refer to Resources
 ANSI / RIA R15.06-12
 OSHA Standards
 CUL / UL [Underwriters Laboratories]
 Hazardous materials requirements
 Local Codes
 Good manufacturing practices
 Plant Standards Robotic Industries Association
PO Box 3724
 Personnel training policies 900 Victors Way
Ann Arbor, MI 48106
(734) 994-6088
www.robotics.org

35
 System Safety Responsibilities

 Robot Manufacturer  System Integrator

 All E-stops are hard wired  Personnel barrier
 Mushroom Button E-Stops  Interlocked safety gates / light curtains
 E-Stop switches strategically placed
 Enabling device
 Awareness barrier
 Robot velocities are constantly monitored  Status beacon or signal
 Teach and Check velocities are reduced  Maximum envelope marking
 Joints equipped with Hard Stops or Safety-Rated Soft  Behavior management
Axis Limiting Devices  Training
 Joints equipped with Hard Stops  Risk Analysis
 Joints equipped with over-travel limit switches
 All robot axes have software limits for work space  End User
 Velocity and deviation errors are constantly monitored  Behavior Management
 All axes equipped with electromechanical brakes  Personnel training
 Crash software  No tolerance on misbehavior
 Maintain safety equipment
 Error messages
 Risk Analysis
 Training

Resources in Robot Safety

 National Robot Safety Conference

 Held annually in the fall in a Central U.S. location

 In House Safety Training

 Robotics Online e-Newsletter
 Workshops, Forum, Webinars and Conferences
 Integrator Certification Program
 RIA Resources and Books
 Ask the experts

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 Basic System Process Control

 Process Control
 Communication to external equipment and production system
 Operator Control of entire system
 Philosophy with robot controller
 Define where event is to occur in robot path – at end of move?
 What action is to occur when the event happens
 Program / Product Selection
 Auto Start of entire line
 Process Monitoring
 Data Collection
 Diagnostics
 Maintenance
 Quality Control
 Process Flow

System Control Philosophy

 Philosophy 1
 Robot Controller does all
 System I/O, Tooling Control, Motion Control, Operator Interface

 Philosophy 2
 Robot Controller
 Tooling Control, Motion Control

 PLC or PC
 System I/O, Operator Interface

 Philosophy 3
 Robot Controller
 Motion Control only

 PLC or PC
 System I/O, Tooling Control, Operator Interface

 Philosophy 4
 Robot Controller
 Robot Drives only ( dumb motion controller )

 PLC or PC
 System I/O, Tooling Control, Operator Interface

 System Controller has kinematics for the arm

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 Crashes

 Crash Avoidance
 Software Limits
 Hard stops
 Programming
 Speed reduction in teach and check
 Priority in Multiple robot cells
 Master / Slave
 Crash Detection
 Feedback
 Mechanical Means
 Crash Detection Software

10+ Mistakes in Robot System Integration

 Underestimating Payload, Torque and Inertia.
 Expecting the robot to do to much.
 Overlooking the need for options or peripheral equipment
 Underestimating Cable Management Issues.
 Not considering all current and future application needs
 Misunderstanding accuracy and repeatability.
 Not fully utilizing the capabilities of a robot
 Choosing a robot or system solution solely on price
 Failure to consider using robotic technology.
 Thinking that robots are to complicated.
 Focusing on the robot alone.
 Not planning for disaster.
 Not selecting the “easy” application first

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 The Business Case for Robotics and Automation Dollars
Robots and the Robotics Industry
Robot and System Technology
Applications

System Applications

 Spot Welding
 Arc Welding
 Coating & Dispensing
 Less than 10 pounds
 Greater than 10 pounds
 Assembly
 Less than 10 pounds
 Greater than 10 pounds
 Material Handling
 Packaging / Palletizing
 Machine Tending
 Body Shop
 Other Material Handling
 Material Removal
 Inspection

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 Spot / Resistance Welding

 Product
 Body in White
 Very Common Application in Automotive
 Motivation
 Bulky and heavy Welding Gun
 Significant Labor Savings
 Consistency in weld process
 Numerous welds per station
 Shortens production line
 Easier line changeover

Automotive Paint
 Product
 Automobile Body
 Motivation
 Fully automated system
 Automated color change based on production menu
 Person is not in the breathing apparatus
 Person is not in Explosion Proof area
 Finish Quality
 Production Speed Needs

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 Coating and Dispensing

 Products
 ATV Wheels
 Oven Enameling
 Motivation
 Person is not in the breathing apparatus
 Person is not in Explosion Proof area
 Finish Quality
 Production Speed Needs

Assembly

 Product
 Wiring Fluorescent Light Fixtures
 Bending Orthodontic Braces
 Very Tedious Process done manually
 Motivation
 Eliminated difficult manual process
 Improve quality of wiring
 Reduce wire use
 Reduced pre-wiring operations
 Standardized assembly

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 Material Handling
Shoe Polish Packages, Solar Cells, Raw Chickens, Vials

Material Handling - Palletizing

 Product
 Bags
 Motivation
 Eliminates Back Strain from Lifting
 Eliminates Repetitive motion
 Labor Savings
 Requires numerous people per line
 Difficult to get people to do this task
 Quality of stack
 Cost reduction

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 Material Handling - Packaging
 Product
 Cookies
 Frozen Egg Rolls
 Motivation
 Speed Requires many people
 Repetitive motion causes injuries
 Labor Savings
 Difficult to get people to do this task
 Quality of Package
 Cost reduction

Machine Tending
 Product
 Injection Molded Plastic Head Rest Parts
 Forged Bearing Housings
 Motivation
 Combines Operations
 Eliminates Repetitive motion
 Labor Savings
 Difficult to get people to do this task
 Cost reduction

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 Pork Ham de-boning

 Product
 Hams
 Motivation
 Eliminates risk of contamination
 Removes people from wet area
 Eliminates possibility of cuts
 Increases yield (> 95%)
 Huge cost savings

Material Removal - Water Jet

 Product
 Cutting Jet Ski Bodies
 Deburring Castings
 Motivation
 Person not exposed
 Labor Savings
 Quality Improvement
 Cleaner holes
 Cost reduction
 Consistency
 Standardization of parts
 Combined Operations and reduced cycle time

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 Machining
 Product
 Drone Frames
 Motivation
 Quality Improvement
 Response to changes / customization
 Consistency
 Highly accurate

Material Removal - Grinding

 Product
 Gears
 Motivation
 Highly Accurate
 Repeatable Process
 Consistency
 Highly accurate

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 Robotic Bowling

 Product
 Bowling against a Robot
 Motivation
 No Ergonomic Issues solved
 No Labor Savings gained
 Wins every game

CONTACT INFORMATION
Bob Rochelle
Food & Packaging Industry Specialist

Staubli Robotics
201 Parkway West
Duncan, SC 29334
USA
Telephone: (248) 924-6206
email: b.rochelle@staubli.com
www.staublirobotics.com

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