AUTOMATION & ROBOTICS
PickMaster 3 makes full use of the capabilities of all three robots in the system, minimising the number needed and helping save space. To prove the system design was viable, MES Koshin used ABB’s RobotStudio Picking PowerPac simulation software. “G-TEKT and MES Koshin looked at the unique
characteristics and range of FlexPickers. Together with the PickMaster 3, they have created a system that maximises the capabilities of the ABB robots. We would like to thank G-TEKT and MES Koshin for their efforts.” says Shuichiro Nakajima, Head of Robotics & Discrete Automation Business Unit, ABB.K.K. “In this project, we worked with MES Koshin to refine the final specifications, discussing the number of robots and how to meet the challenges and constraints of installing the equipment. Space and speed were very important issues for us,” says Akio Kato, Plant Manager of the Tochigi Plant, Production Division of G-TEKT Corporation, who led the project for the end customer. The automation processes are divided into two
sections: the visual inspection process and the loading onto the pallets. The visual inspection uses AI-based equipment to give a resolution as close as possible to that achievable by a human eye, without being dependent on the operator’s skill level and physical condition.
GREATER PRODUCTION VOLUMES Mr. Yoshiaki Ozawa, Director, Sales Manager and Production Manager at MES Koshin, says: “We used
RobotStudio and Picking PowerPac to carry out a number of simulations to check the feasibility of the system, and finally were able to finish the operation on site and achieve a production volume that even exceeded our expectations.”
“In order to cope with the large number of
products, 17 vacuum cups are arranged in a row and each of them can be switched by one hand. We have even managed to set up the system so that the robot does not stop tracking when a worker is present to retrieve and change pallets,” Mr, Ozawa added. Commenting on the benefits of the automation
project, Mr Kato said, “Firstly, we were able to automate the work of four workers in two shifts, allowing us to free up these employees to do more creative work. In addition, productivity has increased by around 10 percent, and we can now produce around 19,200 more sheets per day. From the view of an operator, I believe it is important that the equipment does not stop, that it does not break down, and that it is easy to maintain, and they have achieved all of these at a very high level.” Looking to the future, Mr Ozawa concludes: “We
have learnt a great deal about the range of tasks that can be carried out by robots to replace people. We look forward to working with ABB to build more equipment full of ideas for a variety of production sites in the future.”
ABB will continue to work closely with MES Koshin to meet their expectations and help G-TEKT realise the next generation of production facilities.
SUMMARY THE APPLICATION
Inspecting steel blanks that form the basis of automotive components and stacking them on pallets. The components were heavy for human workers to lift safely.
THE CHALLENGE An automated system needed to fit in a very limited space, while maintaining quality inspection standards and increasing productivity.
THE SOLUTION Three ABB IRB 360 FlexPicker with a 6 kg payload and 1600 mm reach, controlled by ABB PickMaster 3 software. Designed to control multiple robots, this system makes the best use of the available space and allows a 10 percent increase in productivity.
ABB Robotics
www.abb.com/robotics
FACTORY&HANDLINGSOLUTIONS | APRIL 2022 47
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