Metrology 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,” explains 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,” continues 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,” continues 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,” concludes Foster.
The Sempre Group
www.thesempregroup.com
Instrumentation Monthly August 2021
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