Robot Solutions

Simply put, an industrial robotic system is a programmable, mechanical device used in place of a person to perform dangerous or repetitive tasks with a high degree of accuracy.

Because robotic systems can be programmed to perform dangerous, dirty and/or repetitive tasks with consistent precision and accuracy, industrial robots are increasingly used in a variety of industries and applications. They come in a wide range of models with the reach distance, payload capacity and the number of axes of travel (up to six) of their jointed arm being the most common distinguishing characteristics.

In both production and handling applications, a robot utilizes an end effector or end of arm tooling (EOAT) attachment to hold and manipulate either the tool performing the process of the piece upon which a process is being performed.

The robot’s actions are directed by a combination of programming software and controls. Their automated functionality allows them to operate around the clock and on weekends—as well as with hazardous materials and in challenging environments—freeing personnel to perform other tasks. Robotic technology also increases productivity and profitability while eliminating labour-intensive activities that might cause physical strain or potential injury to workers.

The term robot comes from the Czech word robota, generally translated as "forced labour." This describes the majority of robots fairly well. Most robots in the world are designed for heavy, repetitive manufacturing work. They handle tasks that are difficult, dangerous or boring to human beings.

The most common manufacturing robot is the robotic arm. A typical robotic arm is made up of seven metal segments, joined by six joints. The computer controls the robot by rotating individual step motors connected to each joint (some larger arms use hydraulics or pneumatics). Unlike ordinary motors, step motors move in exact increments. This allows the computer to move the arm very precisely, repeating exactly the same movement over and over again. The robot uses motion sensors to make sure it moves just the right amount.

An industrial robot with six joints closely resembles a human arm -- it has the equivalent of a shoulder, an elbow and a wrist. Typically, the shoulder is mounted to a stationary base structure rather than to a movable body. This type of robot has six degrees of freedom, meaning it can pivot in six different ways. A human arm, by comparison, has seven degrees of freedom.

Your arm's job is to move your hand from place to place. Similarly, the robotic arm's job is to move an end effector from place to place. You can outfit robotic arms with all sorts of end effectors, which are suited to a particular application. One common end effector is a simplified version of the hand, which can grasp and carry different objects. Robotic hands often have built-in pressure sensors that tell the computer how hard the robot is gripping a particular object. This keeps the robot from dropping or breaking whatever it's carrying. Other end effectors include blowtorches, drills and spray painters.

Industrial robots are designed to do exactly the same thing, in a controlled environment, over and over again. For example, a robot might twist the caps onto peanut butter jars coming down an assembly line. To teach a robot how to do its job, the programmer guides the arm through the motions using a handheld controller. The robot stores the exact sequence of movements in its memory, and does it, again and again, every time a new unit comes down the assembly line.

Most industrial robots work in auto assembly lines, putting cars together. Robots can do a lot of this work more efficiently than human beings because they are so precise. They always drill in the exactly the same place, and they always tighten bolts with the same amount of force, no matter how many hours they've been working. Manufacturing robots are also very important in the computer industry. It takes an incredibly precise hand to put together a tiny microchip.

The vision system enables a robot to see and identify various objects. The system provides the robot with an ability to collect the light reflected from the objects, process an image out of it and then perform the desired action. The vision system helps with these functions by using various hardware systems to accurately pick and place parts whilst also checking for defects.

Vision systems can dramatically enhance robotic capabilities. Without vision, “blind” robots are relegated to performing the same repetitive task, until programmed to do otherwise. Robots with robot vision systems have much greater flexibility and functionality because of their ability to react to variables in their environment.

Vision systems provide many benefits for robotic automation. When robots have the flexibility to automate multiple tasks, this maximizes return on investment (ROI), as lower levels of investment are required for greater levels of automation.

Vision systems can often replace manual processes and other automation equipment too. For example, vision guidance for a robot can replace the need to invest in costly fixtures, as well as the cost of loading and unloading those fixtures.

Robotic vision systems vary widely in form and function – they can be 2D or 3D, they can be embedded onto the robot or operated separately, and they come in a wide range of resolutions and imaging capabilities. Regardless, they all have the potential to provide ROI benefits and operational cost savings.

Not all robotic applications require a vision system, but some operations benefit greatly from a robotic vision system. They’re an additional automation investment, but they can help deliver great returns.