FEATURE Robotics
Feature sponsored by
Six-station machine tending M
anufacturers use automation to take their operations to the next level. Whether it is
increasing throughput or decreasing labour costs, the integration of robotics gives enterprises of all sizes the opportunity to expand their business and eliminate pain points in their processes, which often has a ripple effect of unforeseen benefits. When Battery Builders (BBI)
from Naperville, US, decided to upgrade industrial lead-acid battery manufacturing facility, it seemed like an obvious choice to include a six- station COS (Cast-On-Strap) machine. It worked with robotic integrator MAC Engineering to install a Kawasaki large-payload robot with a robotic cell consisting of six process stations. Almost immediately after installing this robot, BBI saw a more consistent product – an unforeseen benefit that will likely have a huge impact on its business going forward.
Challenges The robot had to have a high payload and high repeatability in order to accurately lift and align the battery plates. BBI also needed to rely on its robot and peripheral equipment to meet production goals of 1,000 battery cells per day – more than double its current daily production – with less manpower. BBI was plagued by frequent machine breakdowns from its manually-run COS machine, which was over 25 years old. The antiquated machine was causing delays in production, with BBI was experiencing four to five hours of downtime a week.
The manual stacking of battery plates and loading them into jars generates more airborne lead dust. The older machine also required employees to lift heavier loads, resulting in a greater risk of injury. BBI had to install a workhorse precise enough to consistently align 300lbs of battery plates up to 500 times per day. The robot also needed to be able to brush off the batteries’ end connectors, dip them into molten lead, and package them in plastic jars, among other tasks. To meet all these diverse tasks, BBI needed a versatile robot.
14 September 2022 | Automation
Solution
Following the installement of the Kawasaki robot, BBI saw the benefits almost immediately: There was a visible change in the product quality. Not only the robot is precise in its movements, but it automates well with all the equipment around it, too – yielding a more accurate product.
In addition, the number of people needed to handle the processes dropped from seven to five. The robot steps in after the battery plates have been manually slid onto the conveyor, to align the plates and ensure they are even and flush. During this new process, operators no longer have to lift the plates from the ground – the plates are laterally moved onto a conveyor, in an ergonomically-friendly manner. From here, the robot picks up the plates and runs them over a large bristle brush to remove any lingering debris from the end connectors, called lugs. Next, the robot runs the product through a flux process. The lugs are then dipped into tin and dipped again into molten lead. Last comes the case out process, where the robot places the battery plates into their plastic casing. Although Kawasaki’s ZX300S robots are capable of carrying payloads to 300kg, they combine a long reach arm with a minimal amount of dead space for a
wide work envelope. They also have a high repeatability of ±0.3mm, making them ideal for applications that require precision and heavy lifting. When combined, these features created the perfect solution for BBI’s setup, which required the robot to be able to reach multiple machines at varying heights. Kawasaki’s newer large payload
robots, the B and CX series, have even higher repeatability, ranging from ±0.06 to ±0.08mm. Both series have a hollow arm structure, which allows for internal dressing of the robot. This feature simplifies installation by reducing the amount of time needed for manufacturing line builds and digital engineering, and minimises the risk of interference with other robots or peripheral equipment.
Results
For BBI, working with the new robot made its processes very easy: from installing the robot, through learning how to work with, to the functionalities and benefits it brought with it to the company.
CONTACT:
Kawasaki Robotics (UK)
https://kawasakirobotics.de/en/ 01925 713000
automationmagazine.co.uk
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