ROBOTICS
camera monitoring a continuous stream of keys on the conveyor. Upon triggering, the camera captures an image and uses its in-built contour detection to locate each key. The camera then sends the position of each key to the robot controller via TCP/IP Ethernet communications. “Integrating the vision system and encoder with the new generation TS5000 controller presented some initial teething issues,” explains Smith. “However, the user-friendly interface of the controller and the Shibaura Machine robot teach pendant made the integration process significantly easier. Our robot experts worked collaboratively with M.A.P Services to ensure seamless integration.”
The robot syncs with the IFM encoder for accurate conveyor tracking, picks up the key with a suction cup and carries it to the drop point. There, it waits for a signal from the nut-filling machine before releasing the key. This cycle repeats every second, ensuring a high-speed operation that leaves no room for error or delay.
INSTALLATION AND RESULTS The project exceeded all expectations. The automated system exceeded the cycle time requirement, achieving higher efficiency and reliability. In fact, Freedom Fresh Australia
UKManufacturing Autumn 2024
expressed immense satisfaction with the solution. “Our experience with the new system has been an eleven out of ten,” explains Trevor Steinhardt of Freedom Fresh Australia. “The job of placing keys into bags was a difficult one, and there was no mechanical solution we could find. Now, the system just runs. It is coping very nicely and the strike rate is far better than a human operator.”
Joel Spiteri, the engineer from M.A.P Services that installed and commission the system added, “The first robot installation took place in July 2023, and it has performed flawlessly ever since. What’s more, the impressive results led Freedom Fresh Australia to order three more identical systems. Two of these robots are designed to work in tandem, further increasing cycle times and productivity. The additional robots were installed in early 2024 and are currently in the final stages of commissioning.”
When detailing the success of the project, Spiteri cited several factors. “First, the advanced technology of the Shibaura Machine SCOL, combined with the precision of the IFM O2D camera and encoder, which ensures accurate and rapid key placement. Second, the seamless integration of the THE400 SCARA robot with the conveyor tracking system and vision system to
facilitate smooth operation.” The collaboration between TM Robotics and M.A.P Services was also noted as instrumental to the project's success. Throughout the design, installation and commissioning stages, M.A.P Services and TM Robotics maintained a collaborative approach. Regular online meetings facilitated effective communication and problem-solving. "Lastly, it was the customer-centric approach that delivered outstanding results,” adds Spiteri. “We ensured that we understand and addressed the specific needs of Freedom Fresh Australia. This effort led to a tailored solution that has exceeded the customer’s expectations.”
FUTURE PROSPECTS
Encouraged by the success of this project, Freedom Fresh Australia plans to further explore automation opportunities in its production processes. While automating processes like this one can be a tough nut to crack, leaning on the local expertise of M.A.P Services and the support of Shibaura Machine distributor, TM Robotics, for robot consultation can be the ‘key’ to achieving success.
TM Robotics
www.tmrobotics.com
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