FEATURE Robotics
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E
lectroplating features in many manufacturing processes and if performed manually can require a considerable space and human
resources. However, a good example and robotics is the development of an innovative robot cell that enables fully- automated electroplating – it has already automation company, Roth Technik. A three-way collaboration between the customer, surface-coating specialist Collini based in Dubendorf, near Zurich, with automation company Roth Technik and sensor specialist Baumer has resulted in the development of a fully-automatic system for plating racks. Minimal space was a key factor for the customer, which is why they were looking for a space- saving solution that would allow a fast and reliable way of hanging small parts on racks in preparation for transfer to the electroplating bath. Marco Fuchs, Head of Product Engineering at Collini explains: “Boxes containing small metal parts were stacked in a narrow niche with barely enough space to manoeuvre a single pallet between the wall and the liquid tanks. Behind this assembly are rows of tightly- packed electroplating tanks, and this lack of space was a key factor in why we were looking for a space-saving solution that would deliver a fast, reliable way of hanging small parts on racks for the electroplating bath”.
The conventional method of loading the racks by hand requires lots of space and human resources, as several racks need to be loaded at the same time. Fuchs says: “This is why we wanted to switch to a new automated coating system. However, this type of system had yet to be created, so we embarked on a search for pioneering companies that we could collaborate with to take up the challenge”. The search resulted in the collaboration between Collini, Roth Technik and Baumer. Working together, the team began the development of a fully-automatic and compact loading line. At the heart of the loading line are four robots that automatically load parts onto empty hooks
30 April 2024 | Automation
on the racks, with the biggest challenge being that no two racks are the same. The hook positions are not located in exactly the same place on the welded racks and some hooks may be bent or missing entirely. Whilst this isn’t a problem for a manual system, it is a big challenge for robots that require precise positioning data. Furthermore, the huge variety and high throughput of parts presented other challenges.
of rack positioning accuracy, enabling the robots to learn the exact positions of the hooks for each rack? sensor, proved to be a key component in arm, the sensor detects the exact position of each individual hook as it moves down the rack, and reports the data back to the robot control. With the help of a camera, the robot then picks up one part after the other from the separating carousel and hangs it on a hook. The robot uses the position coordinates the robot precisely and quickly on the electroplating rack.
Markus Roth, CEO of Roth Technik, explains: “Whilst the process might sound simple, it requires the sensor to deliver an outstanding performance. We had to
install a sensor that detects and precisely two-dimensional space but in a three- dimensional one ,too”. Initially, the Roth Technik team tested various camera-based systems and other laser-based scanners, but eventually decided that the sensor was the best way. “In the end, we chose the Baumer best solution for our strict requirements regarding accuracy, ultra-compact design advantage, thanks to powerful, integrated measuring tools, the sensor outputs the measured values for the X and Z coordinates directly in millimetres, calculations in control. This resulted in less integration work on software and enabled Also, thanks to Power over Ethernet (PoE) a single cable is all that was needed to connect the sensor to the control and supply it with power, an important detail when it comes to mounting the sensor on a mobile robot arm. Further time savings are achieved by scanning the hook positions only once when the rack is inserted and as the control stores all the hook positions, the racks don’t have to be scanned each time. The result is that two robot cells handle 15 million parts per year using minimal space whilst eliminating problems associated with a manual system.
automationmagazine.co.uk
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