Collaborative Capping & Assembly Robot

System description:

The Collaborative Capping & Assembly Robot system is a versatile robotic system designed to cap, customize, and inspect jars/bottles and assemble and inspect various models of reducers. It incorporates a Universal Robots 6-axis industrial collaborative robot or a Staubli or Franka Panda 6-axis robot. The functions and components are derived from real industrial components used in the food, pharmaceutical, and cosmetics industries (jars/bottles) or the assembly industry (boxes/pallets).

This Collaborative Capping & Assembly Robot system, designed with the Industry of the Future (Industry 4.0) in mind, meets the main requirements for intelligent and evolving production methods:

• Flexibility & Customization with the ability to produce customized items to customer order
• Collaborative robotics with the Universal Robots robot (ref. MR10) or the Dobot Robot (ref. MD20)
• Conventional robotics with scanners with the Staubli robot (ref. MX10)
• Online quality control with the vision tunnel (ref. MI01)

This automated system can be used independently with, for example, jars/bottles (with UR or Staubli) or boxes/pallets (only with UR or Staubli) or within the flexible ErmaSmart production line.

The main functions of the Collaborative Capping & Assembly Robot are:

• Convey jars/bottles or boxes/pallets from the inlet to the outlet
• In the "Packaging" configuration: Clip a cap onto a jar/bottle - Detect the type of customization (QR code reading) - Apply the type of customization cap required for the product
• In "Assembly" configuration (only with UR or Staubli): Detect the type of assembly to be performed (read the QR code) - Position the lower shaft of the reducer in the base - Assemble the planetary gears on the base (Different planetary configurations possible) - Assemble the central gear

Option:

• Product quality control by vision and rejection of non-compliant products (pot/bottle not properly sealed)

This educational system is primarily intended for driving activities, system control, industrial maintenance, robotics, and automation.

This product comes with a technical and educational file in digital format.

Industry 4.0 topics covered:

• Scalability & Flexibility
• Customization
• Simplified Programming
• Digital Twin
• Mobile robotics
• Collaborative robotics
• Efficient actuators
• CAPM & CMMS
• Digital instructions & MES
• Online quality control
• IoT & communications
• Big data, AI & predictive maintenance
• Augmented reality
• Virtual reality
• Additive manufacturing for tools, etc.

Educational activities:

The Collaborative Capping & Assembly Robot system can be used to carry out the following educational activities in particular:

Electrical engineering

• Discovery and familiarization with the system (functional analysis and study of system technologies)
• Control of electrical parameters of the system (network, power supply, variable speed drive, programmable logic controller, human-machine interface, and control circuit).
• Commissioning and validation of operation of the system (different production modes)
• Adjustment and configuration of installation components (three-phase asynchronous gear motor and its frequency converter)
• Wiring of new sensors and actuators in an eco-friendly manner (improvement and/or replacement of an electrical component in the installation)
• Programming of new cycles for the PLC and the human-machine interface (Tia Portal and WinnCC software provided with a one-year license).
• Diagnosis of one or more malfunctions
• Use of digital tools and communication

Automation & Robotics

• Functional and structural analysis of the system
• Robot programming with dedicated intuitive software
• Programming of production cycles (Tia Portal software supplied with the system)
• Programming of associated peripheral devices (vision, etc.)
• Implementation of IO-Link sensors (reassignment of inputs/outputs, etc.) and the IO-Link vacuum generator
• Programming of the human-machine interface (TIA Portal software supplied with the system)

Production control:

• Production control with choice of operating mode: "assembled objects" or "capping, inspection, and customization."
• Production format change with integration of new magazines and new positioning.
• Production control with vision tunnel
• Development of operator assistance procedures
• Production optimization with Industry 4.0 digital tools

Industrial maintenance:

• Preventive maintenance (conveyor, suction, etc.)
• Corrective maintenance (fault diagnosis using the TIA PORTAL basic software supplied with the cell, etc.)
• Improvement maintenance (addition of sensors on the conveyor, scrap management, vision control, etc.)

Mechanics

• Study of a robotic workstation, ergonomics, robot and actuator sizing, etc.
• Design of 3D-printed parts
  
  

Key strengths:

A true industrial system with modern technologies

Simple programming of collaborative robots

Production flexibility (Use in "Packaging" configuration with jars/bottles or in "Assembly" configuration with boxes/pallets.)

Customization of production to customer order: parts stores adaptable to different manufacturing processes.

Online vision-based quality control (optional).

System can be used in the fields of electrical engineering, industrial maintenance, and automated system control and management.

Supplied with TIA Portal and WinCC programming software (1 year) for programming the programmable logic controller and dialogue terminal.

IO-Link technology with IO-Link master, Monéo Configure visualization/configuration software, and photoelectric sensors.

Extensions possible to the ErmaSmart flexible production line.

References:

MI00+MR10: Collaborative Capping & Assembly Robot (UR5 eSeries) with tools and set of magazines for "Packaging" configuration

MI00+MD20: Collaborative Capping & Assembly Robot (Dobot CR5) with tools and set of magazines for "Packaging" configuration

MI02: Tools and sets of magazines for "Assembly" configuration

MI01: Vision control option for the Ermasmart 4-axis collaborative robot

UR21: Option: Set of two laser scanners for secure multi-zone management of movement speeds, for Ermasmart

UC90: Fault box option for electrical cabinet, remotely configurable on tablet (not supplied)

UC50: Visual instructions & production indicator monitoring option for line manager on the Tulip open application environment

UC52: Visual instructions option on the Tulip open application environment and touchscreen tablet, for one machine (with 3-year subscription to TulipStandard, €570 excl. tax per year thereafter)

UC41: Siemens remote console option on iPad tablet (included)

IO00: Electrical (Modbus-TCP) and pneumatic (IO-Link) measurement sensor pack

Taqtile-MI00: Augmented/mixed reality operation assistance scenarios with Taqtile Manifest on the Collaborative Capping & Assembly Robot (Commissioning - Format change). NB: Taqtile Manifest Full or Operate license not included, to be purchased separately

TQ//TaqtileManifestFull-1Y: "Manifest Embedded Full" augmented reality visual instruction software (creation of AR scenarios, use of scenarios with user tracking): Academic annual license

TQ//TaqtileManifestOperate-1Y: "Manifest Operate" augmented reality visual instruction software (use of scenarios without creation capability): Annual academic license

ME//MetaQuest3-512GB-W/1Y: Meta Quest 3 virtual reality headset - 512GB 8GB RAM 2064 x 2208 pixels per eye 2 controllers Charging cable and AC adapter 1-year warranty