1) What is the maximum weight that the gripper can handle without the item slipping during movement?
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For the automation solutions we provide, the only limitation is based on the payload capacity of the robot. We customize systems to align perfectly with your requirements, ensuring you're equipped with a solution that works effectively for your operations. If your needs evolve, no worries—our systems can be conveniently adjusted in the field, ensuring you can adapt to changes in production needs. The most substantial robot in our repertoire can lift parts weighing up to 60 lbs. Even the smallest systems come with a grip strength of 100 lbs per finger. While electric grippers work well for tiny components, they may often be the weakest link in the whole setup, potentially limiting the robot's capabilities. It's essential to examine the clamping force of any gripper you consider and compare it with available market options to guarantee it serves your needs adequately.
2) If the robot's stand is accidentally hit after programming it for production, what will happen?
Our stands feature precision locating plates affixed to your concrete flooring, eliminating the risk of displacement. Every time you return the robot, it is positioned exactly as it was previously, which means you won't need to re-teach any points within your robot program, allowing for increased focus on production rather than setup.
3) What financial and time implications come with relocating the system to another similar machine? Is transfer possible between a mill and a lathe, and how long would the process take?
Transitioning the system to another similar machine involves costs under $500 for hardware adjustments, enabling repeatable relocation. Should automated work holding be necessary in a new machine, the costs would vary depending on the application. Setting it up the first time requires roughly an afternoon. Subsequent relocations can be completed in under 20 minutes due to the use of master quick disconnects for wiring and pneumatics combined with our locating feet, which eliminates the need for reprogramming the robot. If your aim is to transfer a system between different types of machines (like a mill and a lathe), you’ll need the aforementioned hardware, new infeed tools, and a different robot gripper, which can be swapped in under an hour.
4) How many components can the robot infeed accommodate?
We have quantities indicated for various infeed options on each of our system's product pages for standard configurations. However, we can efficiently design custom infeeds to suit any required unattended runtime.
5) Is it feasible to customize the robot program for unique tasks relevant to our process?
Absolutely! Given the advanced programming capabilities of UR robots, we refrain from utilizing proprietary software over the standard UR interface as it often restricts your ability to modify the program as needed. Be cautious of third-party software that isn’t built by the robot manufacturer, as it can limit functionality and necessitate continual updates in line with the robot manufacturer’s software advancements.
6) Considering the rapid evolution of this market, how adaptable is your system for compatibility with new products? Is your system future-proof?
Our automation systems are engineered to be modular, ensuring compatibility with a wide range of products available in the market. This trait is crucial given the swift changes in the industry, allowing for upgrades without necessitating a complete system overhaul.
7) How does your system respond to a situation where a particle falls into the workholding area after a clean but before loading a component?
This is a vital query, as many automation systems lack problem-solving capabilities. Our robots are programmed to act based on environmental feedback, preventing stalling over trivial issues. For instance, if a part cannot be seated properly, the robot will automatically remove it, clean the workholding area, and attempt to reload the part. Should it struggle three times, it will place the incomplete part aside and proceed with another attempt. We have similar troubleshooting measures integrated into our entire system.
8) If I revert the system to a previous machine, will I need to retune any robot program points?
No! Thanks to our stand locating system, the operator need not worry about re-teaching the program since the robot returns to the exact position every time. Be wary of other solutions that only ensure repeated positioning in the X and Y axes without Z axis alignment. If Z isn’t accounted for, re-teaching will be necessary each time you move the robot.
9) Do you provide on-site training and installation as a part of your service?
Yes! Our systems come with comprehensive turn-key service, ensuring you can start your operations immediately after installation. This allows you to concentrate on programming parts instead of getting the robot integrated.
10) Can I integrate my existing workholding apparatus with your system?
Certainly! We understand that your manufacturing methods differentiate you from competitors, which is why we strive to automate your current fixture design or the vise you already utilize!
11) My knowledge of the robot's payload capacity suggests a longer gripper will not affect it, provided its weight is unchanged. Is that accurate?
This aspect can be misleading when selecting a robot. Inquire with collaborative robot suppliers whether you can hold a part at the maximum payload several centimeters from the robot’s tool flange. This phenomenon, known as the payload curve, often sees most collaborative robots lose significant payload capacity when the item is held further away from the robot. However, this isn’t an issue with UR collaborative robots.
12) Am I able to operate the robot at maximum speed while carrying a full payload and at the full extension of the arm?
Inquire of the collaborative robot vendors if you can maintain the maximum payload several centimeters from the tool flange while the robot runs at full speed and extension. This distinction is crucial in determining the robot's performance capabilities; with a UR collaborative robot, this is not a limitation. Competing options may push you towards larger robots, incurring unnecessary expenses.
13) How repeatable is the robot's arm, and why is that significant for my operational reliability?
The repeatability of equipment is crucial for process reliability, which is something every machinist understands! Ensure to compare these repeatability metrics with other collaborative robots available in the market.
14) What level of repeatability does the infeed have when the robot picks up components? How will this influence my robot program?
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When the robot does not pick parts from a precisely known location consistently, you can expect equivalent variation when loading them into the machine. Employing a part-locating fixture can mitigate this issue, but we design our infeeds to ensure accurate part gripping every time, right from the start.
15) Can your system execute multiple machining operations on my parts, or is it limited to one operation at a time?
We encourage all our clients to allow the robot to handle all tasks, adhering to the single-part methodology in lean manufacturing to minimize work-in-process. Our setups can run parts through various sequential work-holding devices, enabling completion of a finished part from raw material every cycle.
16) What is the time taken for your system to load parts from when the machine door opens to when it closes?
This is largely dependent on the specifics of the part, but many of our systems can manage the loading of a mill part through an initial and subsequent vice within 40 seconds from opening to closing the door. This process also includes unloading the final part, flipping the half-finished part in the initial vice to the second vice, and inserting a new piece of stock into the first vice.
17) What is the size range of parts that your system can handle?
Our standard systems are capable of accommodating parts significantly larger than what competitors can manage, typically handling up to 60 lbs. While numerous variables are involved, we see our capabilities measured in feet compared to others adhering to inches.
18) Is the robot able to modify the program within the machine? Can it interact with macro variables in terms of both reading and writing?
Absolutely! Be cautious of systems that communicate with the machine solely via discrete I/O; such arrangements can complicate troubleshooting and limit communication complexities between the robot and machine.
19) Do I have to notify the system when adding components to the infeed or removing them from the outfeed?
Not at all! Our robust programs harness the intelligence of the robot to work more efficiently. By employing what we refer to as ‘seek mode’, the robot can adjust its actions based on whether new parts have been added to the infeed or removed from the outfeed, allowing for seamless ongoing operations without manual input.
20) Is a safety risk evaluation necessary for your system? Am I responsible for carrying that out?
According to the Industrial Robot Safety Standard, ANSI/RIA R15.06-, a risk assessment must be performed for every robotic system. A robot risk evaluation systematically identifies and manages potential hazards. Should you integrate the system yourself, this responsibility will fall to you. We provide a comprehensive safety risk assessment that complies with ISO standards for every customer.
21) Does this robot operate faster than in collaborative mode? Is safety scanning required to enable that?
Certainly. Universal Robots can operate faster than in collaborative mode; however, maintaining safety requires proper safeguards to avert injuries. Thus, we equip every system with laser safety scanners, custom-programmed to suit your environment and safety criteria without hampering processing speeds.
As you explore potential partners for automating your manufacturing processes, especially in the medical and life sciences sectors, asking targeted questions is crucial. You should probe into aspects such as product quality and defects, speed to market, efficiency, and the partner's experience before making your decision. Our eBook contains additional insights, but here's a foundational overview to get you started.
Can automation enhance quality and mitigate defects?
Quality assurance and defect reduction are pressing challenges for several manufacturers today. In environments with a considerable number of operators, quality control issues often result from manual processes or ambient factors like contamination. A primary method to address quality concerns is to minimize manual interventions, thereby removing process deviations. An automated system guarantees consistent results each time, decreasing the likelihood of contamination, particularly in sensitive operations.
Recently, Intec Automation aided a client in developing an automated manufacturing workflow to address issues related to quality and defects. This specific client needed to weld delicate materials onto a plastic tray, utilized for growing cell cultures associated with cancer research. The materials in use were remarkably sensitive, where any contact could compromise their integrity. By automating this welding process, human touch was minimized, allowing for thorough monitoring and tracking at each stage to uphold quality standards.
Intec's collaborations extended to helping clients create automation equipment for pharmaceutical-grade filter materials, culture cell growth assemblies, PCR tubes for molecular biology, and multi-well plates for laboratory applications. The recurring requests in these projects often include:
- Heightened precision and accuracy for consistent high-volume production at minimal costs.
- Increased uptime and productivity rates.
- Reduction in contamination risks.
- Capability to manufacture products under varying conditions, such as lower temperatures, humidity, and light—conditions stipulated by machine processes but which manual processes can hinder due to comfort and safety necessitating criteria.
The unique requirements within the medical and life sciences realm necessitate standards for automation equipment that differ significantly from other industries. Medical applications often require cleanroom scenarios, meaning that the materials and construction of the equipment are paramount, given the need for enhanced sanitation practices. Equipment must allow for efficient cleaning and consider designs that diminish the likelihood of contamination points.
Intec Automation provides support to navigate the complexities of validation and regulatory requirements specific to the life sciences sector, including design qualifications that are often irrelevant in non-medical contexts. Additional validation services can be sourced through Intec's affiliated company.
What is the anticipated lead time for automation projects?
Time to market constitutes yet another crucial consideration in partnering with assembly automation companies. The validation process can be quite prolonged, with machines sometimes remaining idle on a client’s floor for up to a year before achieving full validation. Thus, it is imperative that the partner you select is transparent regarding timelines and expected lead times.
Intec recognizes that expediting system delivery to customers accelerates their validation efforts and promotes quicker market entry.
Will automating truly afford the speed I require?
Speed remains a primary motivator behind manufacturing automation today, with manual endeavors often hindered by internal delays. The elimination of such impediments via automation allows for enhanced throughput, leading to reduced defect and waste rates.
Reports from various companies indicate that their Overall Equipment Effectiveness (OEE) operates at around 50-55% in manual conditions. In contrast, transitioning to full automation sees that OEE figure soar to approximately 85%, showcasing significant enhancements in operational efficiency.
Does your company possess ample experience in building solutions for my particular product types?
Precision and accuracy are vital within the life sciences sector, so when you initiate your search for a partnership, seek out firms that have a solid track record in producing high-tolerance solutions tailored to your unique product requirements.
With over 20 years of successful project delivery, Intec Automation is equipped to collaborate with manufacturers globally in crafting tailored automated solutions to streamline their operations.
For more inquiries or deeper insights, feel free to explore our eBook, which serves as a resource for selecting the right partner for your future automated manufacturing needs.
If you would like to secure your profitability through an automated manufacturing solution, do not hesitate to reach out to our engineers today.
For further information, please visit Automation Equipment Precision Parts.
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