Manufacturers Guide to Robotics

Home , Articulated robot

PURPOSE OF THIS GUIDE This guide serves as an introduction to the most common types of robots and robot accessories AUTOMATION OPPORTUNITY on the market. It also presents initial steps to % REMAINS IN 60% OF help you understand how robotics can add value 60 MANUFACTURING TASKS in your organization. Robotics have traditionally been thought of as a singularly focused and costly system exclusive to large manufacturers with low mix/high volume production. Recent technology advances in sensors, software, vision systems, and AUTOMATION POTENTIAL more are shifting that paradigm and making robotics % INCREASES TO OVER 80% FOR implementation accessible and feasible for even the 80 PRODUCTION ORIENTED TASKS smallest manufacturers.

Robotics have been a key element in improving efficiency and safety in manufacturing, particularly in the automotive and electronics industries, for SMMs MAKE UP 99% OF decades. However, it is estimated that automation ALL MANUFACTURING potential remains across over 60%1 of manufacturing % 99 ORGANIZATIONS IN THE tasks, a figure that increases to over 80% for UNITED STATES production oriented tasks. This is particularly true for small and medium manufacturers (SMMs), which make up 99%2 of all manufacturing organizations in the United States. As SMMs grapple with upwards of two million positions unfilled through 20253, 1 https://www.mckinsey.com/business-functions/ exploring robotics is a valuable step. While not a operations/our-insights/human-plus-machine-a-new- “one size fits all” solution, robotics can often help era-of-automation-in-manufacturing SMMs achieve benefits such as increasing production with the same workforce, eliminating or reducing 2 Source: U.S. Census Bureau production bottlenecks, and improving worker satisfaction by redeploying workers to more value- 3 https://www2.deloitte.com/us/en/pages/ added tasks. manufacturing/articles/boiling-point-the-skills-gap-in- us-manufacturing.html

ROBOTICS IN MANUFACTURING INTRODUCTION | 1 ARTICULATED

 PICK AND PLACE  MACHINE TENDING  ASSEMBLY  WELDING  PACKAGING  PALLETIZING  INSPECTION  MATERIAL REMOVAL  DISPENSING

An articulated robot is the type of robot that comes 4 and 7-axis units on the market. Key specifications to mind for most people. Similar to a human arm, include payload (end of arm tooling + work piece) an articulated robot is classified by the number of and reach. This ranges from 1lb (0.5kg) and 10.2” points of rotation or axes (joints) such as the most (260mm) on the smallest of articulated units up to common, the 6-axis articulated robot. There are also 5,000lb (2,300kg) and 181” (4,600mm) on the largest industrial units.

ADVANTAGES DISADVANTAGES High degree of flexibility, dexterity, and reach Flexibility and dexterity comes at a cost. Higher makes articulated robots ideally suited for tasks cost compared with other robot types of operating between various, non-parallel planes, comparable payload. Less suited for very high- such as machine tending. It can easily reach into speed applications due to more complex kinematics a machine tool compartment and under (or even and relatively higher component mass than other around with 7th axis) obstructions to gain access to robot types. Precision degrades on outer limits of the workpiece. Sealed joints and available protective payload/working range, although modern control sleeves allow them to excel in clean and dirty systems can compensate. environments alike. Ability to mount on any surface (ceiling, sliding rail, or mobile robot) maximizes working range options.

2 | ROBOTICS IN MANUFACTURING ROBOT TYPES SCARA

 PICK AND PLACE  ASSEMBLY  INSPECTION  PACKAGING  DISPENSING

Selective Compliance Assembly (or ADVANTAGES Articulated) Robot Arm. Slightly compliant in X-Y, horizontal, plane, but rigid in Z (vertical) Lightweight, pedestal mounted with small direction. Generally a 4-axis unit, with most footprint makes them ideally suited to under 13lb (6kg) payload capacity and 25” applications in limited space. Good at vertical (650mm) of reach. assembly tasks such as inserting pins without binding due to rigidity in vertical direction. Lower cost option to articulated robot when working between two parallel planes, such as pick and place from a tray to a conveyor. Capable of very fast cycle times. SCARA DISADVANTAGES (Selective Compliance Most models are focused on lower payload Articulated Robot Arm) and shorter reach applications, although some — models up to 110lb (50kg) and 47” (1200mm) are available. Due to the fixed swing arm design, Excels at vertical assembly which is an advantage in certain applications, or operations between SCARA robots have limited ability to work around or reach inside an object such as fixtures, jigs, or two parallel planes machine tools within the work cell. (ex. tray to conveyor)

ROBOTICS IN MANUFACTURING ROBOT TYPES | 3 DELTA

 PICK AND PLACE  ASSEMBLY  INSPECTION

Delta robots utilize three base-mounted motors to payload from <1lb (0.5kg) to 26lb (12kg), and reach actuate control arms in a parallelogram arrangement from 15” (420mm) to 63” (1600mm), though they to position the wrist. They are also referred to as are most commonly implemented on the lower “spider” robots. Basic delta robots are 3-axis units; end of the payload/reach range. Use caution when 4- and 6-axis models are also available that utilize comparing reach specifications to other robot types. remote actuated wrist designs. By mounting the Reach for delta robots is typically defined by the actuators on, or very close to, the stationary base circular diameter of the working range, as opposed instead of at each joint as on an articulated robot to the reach on a radius from the base of articulated arm, the moving structure (arm) of the robot can or SCARA units. For example, a delta unit with a be very lightweight. This allows rapid acceleration 40” reach would only have half the reach (20” on a which makes delta robots ideal for very high speed radius) of a 40” articulated or SCARA unit. operations with light loads. Delta units range in

*REACH

ADVANTAGES DISADVANTAGES Design of unit makes it excel at high speed Low payload/reach capabilities. Limited ability to operations; in some applications it can reach 200 work in planes perpendicular to mounting base. cycles per minute. Well suited for placement above Extensive mechanical linkages and gearboxes can a conveyor for pick and place operations. Makes have higher maintenance requirements compared quick work of tasks between parallel surfaces. (ex. to articulated and SCARA units. picking part from passing conveyor and assembling to workpiece)

4 | ROBOTICS IN MANUFACTURING ROBOT TYPES CARTESIAN/GANTRY

 PICK AND PLACE  DISPENSING  ASSEMBLY  INSPECTION

Cartesian robots typically consist of 2-3 linear over two parallel rails, they are referred to as gantry actuators assembled to fit a particular application. robots. The work envelope and payload are only By their nature, Cartesian robots are positioned restricted by the length and capacity of the structure above the intended workspace and can be elevated and actuators. This means they can be small, light above to maximize available floor space and payload (<1 lb / 0.5 kg) units or heavy payload accommodate a wide range of workpiece sizes. (>250lb / 100kg) units that cover an entire production When placed on an elevated structure suspended floor when leveraging bridge-crane type structures.

ADVANTAGES DISADVANTAGES Relatively low cost compared to other types of Unable to easily reach into or around obstacles. robots. Use of standard linear actuators and Exposed sliding mechanisms less suited to mounting brackets minimizes cost and complexity operation in dusty/dirty environments, particularly of “custom” systems. Can cover large work area. on lighter duty units. Structure spans entire Higher capacity units able to integrate other robotic work area. technologies (such as articulated robot) as “end- effector” to increase capabilities of system. High payload capacity when supported at both ends.

ROBOTICS IN MANUFACTURING ROBOT TYPES | 5 COLLABORATIVE VS. INDUSTRIAL

COLLABORATIVE INDUSTRIAL Collaborative robots, also known as “cobots”, Traditional robotic systems. operate at lower payloads and speeds and are equipped with safety systems allowing operation • Significantly higher payload (up to 2,300kg) and together with workers in the same work cell. speed capabilities (up to 10 m/s)

• Operate with lower forces/speeds º Capabilities far exceed collaborative robotics

• Lower payload – typical cobot max of • Safety guarding/systems required due to higher approximately 22lb (10kg), though models up to speed and force capabilities 77lb (35kg) are available º Increases cost over comparable • Able to operate without extensive safety collaborative robot guarding allows significant flexibility/mobility • Higher investment due to significant cost º Operating at highest capable speeds can associated with safety guarding and require safety system integration to reduce systems integration to “collaborative” speeds when workers in • Safety standards close proximity ANSI/RIA R15.06-2012 • Ease of programing through teach pendant or º physically moving unit to “teach” motion º ISO 10218-1:2011

• Safety standards º ISO 10218-2:2011 º RIA TR R15.606-2016

º ISO 15066:2016

COLLABORATIVE INDUSTRIAL

High speed/payload

Comparable speed to human worker

Potential to program and setup in-house

High flexibility to redeploy to multiple applications

High accuracy

High accuracy and speed

Operate near or with workers

Lowest implementation cost

Achieve “lights out” operation

6 | ROBOTICS IN MANUFACTURING GENERAL DISTINCTIONS TOOLING & ACCESSORIES

END EFFECTORS* OTHER ACCESSORIES

Grippers – Most common end effector Force-Torque Sensors. Allows robot to used for manipulation of work pieces “feel” the workpiece and surrounding area. Integrated into robot or mounted at wrist • 2 or 3 finger. Grips wide range of products and shapes Cart/Stand

• Compliant/Adaptive. Ability to adjust • Fixed stand for dedicated application closure path and force to accommodate different material requirements (ex. • Wheel mounted with foot jacks to allow fragile items that could be damaged flexibility to move to various cells in facility with excessive force) • Unique mountings possible – ceiling, • Vacuum. Typically used with flat, non- wall, mobile robot porous materials (ex. sheet metal, boxes) Jigs/Fixtures (Part Presentation). Highly variable by application, but a critical part of º Traditional suction cup designs can be highly customizable – just robot integration. Common to encounter piece together desired structure issues when inadequate focus placed on how to present parts to robot or how the º “Area grippers” utilize pad to robot is able to hand off finished goods grip large area with control valves to provide vacuum only where Vision Systems needed (ex. perforated surface) • Robot Guidance Material Removal – sander, buffer, • Quality inspection – feature presence/ grinder, etc. Often utilize standard tooling location, quantity checks, defect checks modified for use on robot. Some purpose built robotic tooling available • Measurements/gauging

Assembly – screw/nut driver, welder, • Character recognition – recognition (or dispenser (glue/sealant/etc), paint sprayer validation comparing to expected value)

Tool Changers, Dual Grippers – • Print quality inspection allows multiple tools to be used for improved efficiency.

*ALSO KNOWN AS END-OF-ARM TOOLING (EOAT)

ROBOTICS IN MANUFACTURING ACCESSORIES | 7 FIRST STEPS

IDENTIFY RESOURCES TO GET THE LEVEL OF SUPPORT YOU NEED 01 Connect with Catalyst Connection or your local MEP center Connect with vendors and systems integrators through SWPA AR Working group Engage with ARM

IDENTIFY YOUR NEEDS OR PAINPOINTS AND PRIORITIZE 02 Supporting Tools Manufacturing Examples

BUILD A BUSINESS CASE 03 Business Case Components Investment Considerations

8 | ROBOTICS IN MANUFACTURING BUSINESS CASE IDENTIFY RESOURCES

CATALYST CONNECTION AND MEP NETWORK

• Local and Regional support for manufacturing

SOUTHWESTERN PA ADVANCED ROBOTICS ARM (ADVANCED ROBOTICS (AR) WORKING GROUP FOR MANUFACTURING)

• Learn from experts in the field • Member-based consortium with national scope • Gain awareness of relevant events and training opportunities in the region • Project funding and access to project outcomes • Share and learn from mutual challenges and exchange best practices • National network of suppliers, partners, potential customers • Expand your network of peers, suppliers, integrators, and academics • Access to physical, knowledge, or talent resources • Identify development and implementation assistance to support your projects • Insight into advancements, trends, use cases, and best practices

Catalyst Connection and the MEP Network are working together with ARM to extend national reach and support SMMs in the exploration and potential adoption of robotics.

ARM’S PROJECTS DESIGNED TO ADDRESS TECHNICAL & WORKFORCE CHALLENGES

VERSATILITY COLLABORATION

TIME TO DEPLOY/ WORKFORCE ABILITY REPURPOSE & WILLINGNESS

COST/ROI

ROBOTICS IN MANUFACTURING BUSINESS CASE | 9 PAINPOINTS & PRIORITIES

IDENTIFYING NEEDS TOOLS The first step before robotics or any new technology • Internal discussions with key business/ is implemented or expanded is identifying the need operations personnel to establish potential or painpoint. Sometimes that is identified well in needs/painpoints advance through strategic planning or new product introductions, but it is often identified in the moment • Product/process matrix to identify opportunities when it may already have a negative impact on in high-mix, low volume operations your business. Issues like worker safety concerns, • Evaluating effort/complexity/impact to poor delivery performance, or excessive quality start prioritization returns. Every manufacturing environment is different and there are no “one-size-fits-all” solutions, but º Combines internal effort required with identifying your top needs or painpoints is where technology implementation complexity to every manufacturer should start their journey. evaluate priority

EXAMPLE RESULTS AT REAL MANUFACTURERS: CAN YOU IDENTIFY SIMILAR OPPORTUNITIES IN YOUR OPERATION?

ROBOTICS CHALLENGE INDUSTRY NEED/PAINPOINT & SOLUTION RESULT

Custom Engineered, Low Quality control. Current New conveyor supplies Achieved 100% inspection Volume Injection Molder manual inspection of molded ejected parts to cobot with in-process with cobot parts often completed offline, wrist camera; 2-finger gripper implementation. Selected increasing cycle times beyond identifies part orientation and staff trained to identify new allowable limits. Inspection staff presents part to inspection opportunities in automation. needed elsewhere for value camera. Pass/fail quality check Inspection staff reallocated to added tasks. completed, then part rejected more value-added tasks. or delivered to final packaging.

Contract Metal Fabrication Maintain workforce level & Flexible solution to service Existing staff trained to identify (high-mix, low volume) keep pace with production different cells. Implemented opportunities and program needs on press brake and 10kg payload cobot on mobile new jobs. Implemented in stamping operations. Stay stand with 2-finger gripper and production in 1 month with ahead of technology curve and custom vacuum gripper. payback expected in 12-24 fill skills gap. months as utilization ramps up.

Precision Machine Shop Safety concerns. Move workers Proper part presentation Workers happy to work in from dirty sanding task with to facilitate operation. other areas rather than dirty, small parts and hand proximity Implemented 5kg payload dangerous task. Continuing to sanding belt to more value cobot with 2-finger gripper to expand application of added tasks. with 3D printed jaws and part system to other sanding presentation trays on stand operations. integrated with belt sander.

Industrial Component Reshore production of welded Sense exact location of joint Successful reshoring of product Manufacturer components by reducing to be welded on cast parts thanks to 80% reduction in production time and maintain/ with variations. Implemented weld process time and high increase quality. industrial welding robot with quality finished product. two rotating fixtures. Integrate Skilled workers added to laser sensor to determine support reshored process. profile of joint for high quality weld every time.

10 | ROBOTICS IN MANUFACTURING BUSINESS CASE BUILDING A BUSINESS CASE

The discussion of a business case for robotics and automation frequently centers around ROI (return on investment) and payback, which are financial metrics of the success of an investment and can be used to compare competing investment opportunities. These are useful metrics that require tangible, measurable benefits to compare against the total investment as well as investment period.

IDENTIFY BENEFITS INVESTMENT COMPONENTS In addition to tangible and financial benefits, Your potential investment in implementing robotics is a business case should also attempt to include more than just a robot. It is easy to overlook associated intangible benefits of robotics and automation that costs (internal and external) with the excitement over could be impractical or challenging to measure. declining initial cost of some base robotic systems. These benefits would be presented in written Make sure to consider ALL applicable costs when portions of a business case, providing context to evaluating a robotics investment. linkages between implementation benefits and Robotics/automation hardware: robot, end company strategy. of arm tooling, stands, fixtures, trays, vision Quantitative: increased production, system, safety systems, accessories (force- reduced scrap rate (quality), reallocated torque sensor, protective covers, etc), labor hours, reduced labor hours at spare parts, etc. process level, safety (workers comp claims Integration: design engineering, reduction/elimination), increased utilization, installation, testing, ongoing support, WIP reduction, cycle time reduction additional programming needs Qualitative: Employee satisfaction, Internal costs: Technical and production worker retention, attracting best talent, team time (installation, test/acceptance technology “forward” company, keeping trials), training, loss of production revenue edge over competition, safety (general during installation/ramp up, hiring of improvements), production/lot tracking additional technical personnel, finance costs

INVESTMENT CONSIDERATIONS • Maximize return on investment (ROI) by focusing • Building internal expertise (implementation on high utilization applications champion) can reduce reliance on and expense of 3rd party services for ongoing support needs º Collaborative units can accommodate switching between multiple applications/ • Look for units that provide for a wide range work cells of pre-integrated end of arm tooling and accessories. This allows faster and lower cost • Flexibility in system will facilitate re-tooling as (lower risk!) implementation compared with applications evolve or new opportunities arise custom tooling integration. • Complexity of integration is primary driver • Don’t forget to consider part presentation! Some of cost — expect 2-4x hardware cost for tasks, like bin picking, are easy for humans, but complex integrations require additional systems (bowl feeders, fixtures/ trays, vision systems, etc) to automate the process

ROBOTICS IN MANUFACTURING BUSINESS CASE | 11 CALL TO ACTION

JOIN THE SOUTHWESTERN PENNSYLVANIA ADVANCED ROBOTICS WORKING GROUP TO SUPPORT YOUR EXPLORATION OF ROBOTICS

Contact Catalyst Connection to learn more about:

• Service offerings including:

• Robotics/technology project assistance

• Assessments

• Request for Proposal (RFP) development

• Grant funding opportunities

• ARM projects and resources

For more information: www.catalystconnection.org/advanced-robotics-small-manufacturers

12 | ROBOTICS IN MANUFACTURING TAKE ACTION

STRATEGIC PARTNERSHIP SERVICES

Catalyst Connection is a private not-for-profit organization headquartered in Pittsburgh, Pennsylvania. We provide consulting and training services to small manufacturers in southwestern Pennsylvania, accelerating revenue growth and improving productivity. Through active collaboration with our clients and the manufacturing community at large, we contribute to the growth, vibrancy, and ongoing robustness of manufacturing in our region.

Catalyst Connection is supported, in part, by the Commonwealth of Pennsylvania, Department of Community and Economic Development, and by the National Institute of Standards and Technology’s Hollings Manufacturing Extension Partnership.

2000 Technology Dr., Pittsburgh, PA 15219-3110 PHONE: 412.918.4300 FAX: 412.687.2791 TOLL FREE: 1.888.887.7472