Collaborative robot for 2D bulk handling & assembly-screwing

System description:

The 2D Unloading & Assembly-Screwing Collaborative Robot system is a robotic system designed to unload jars/bottles and assemble by screwing the lids onto the reducers. It incorporates an OMRON 6-axis industrial collaborative robot. The functions and components are based on real industrial components used in the food, pharmaceutical, and cosmetics industries (jars/bottles) and the assembly industry (boxes/pallets).

This 2D collaborative robot for unloading and assembly/screwing system is designed with the industry of the future (Industry 4.0) in mind and 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 OMRON robot
• IoT & Communications with RFID tag reading/writing for identification and traceability of customer order packages.

This automated system can be used independently with jars/bottles or boxes/pallets, but can also be integrated into the flexible ErmaSmart production line.

The main functions of the 2D & Screwdriving Collaborative Robot are: Assembly-Screwing Robot are:

• Convey jars/bottles or boxes/pallets from the inlet to the outlet
• In the "Packaging" configuration: Unload jars (different sizes) – Place the jar on the product conveyor
• In the "Assembly" configuration: Unload gearbox covers (different colors) – Place the cover on the gearbox – Screw the cover screws

And optionally:

• Monitor the presence of operators in the area to allow the robot's speed to be reduced/increased.

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

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
• IoT & Communications
• Big Data, AI & Predictive maintenance
• Augmented reality
• Virtual reality
• Additive manufacturing for tools, etc.

Educational activities:

The ErmaSmart 2D collaborative bulk material handling 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-responsible manner (improvement and/or replacement of an electrical component of the installation)
• Programming new cycles for the PLC and the human-machine interface (Tia Portal and WinnCC software provided with a one-year license).
• Diagnosing one or more malfunctions
• Using 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 additional 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 tunnel vision
• 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 (adding sensors to the conveyor, waste management, vision control, etc.)

Mechanics

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

Key strengths:

Genuine industrial system with modern technologies (collaborative robotics, 2D vision, IO-Link, RFID, etc.)

Easy programming of collaborative robots

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

Traceability of customer orders with RFID tag writing

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

Supplied with TIA Portal programming software for programming the programmable logic controller and dialogue terminal.

Omron TM robots are widely used in industry.

IO-Link technology with IO-Link Profinet master (IFM brand) and Monéo Configure sensor visualization/configuration software and IO Link smart sensor (RFID vacuum generator, photoelectric sensor).

Possible extensions to the ErmaSmart flexible production line.

References:

ON10: Collaborative robot for 2D destacking & assembly-screwing: Omron TM5 4kg R900 collaborative robot with on-board camera on mobile frame with conveyor belt and work platform

ON11: "Robotic Screwdriving" pack for the Cobot & Vision Station in "Assembly" configuration

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)

IO01: Electrical and pneumatic measurement sensors (IO-Link) option for monitoring the power, flow rate, and electrical and pneumatic consumption of a machine equipped with an IO-Link master and supervision and preventive maintenance software

Video:

ErmaSmart ON10 2D collaborative bulk material handling robot