Industrial Automation Newsletter by gjjur4356


									                                                                     Industrial Automation
Issue 1 Vol. 2                                                                                                Spring 2009

At Quigg International we take great pride in the way we communicate with our customers. It doesn’t matter if you are
new to automation or experienced, we will take whatever time is required to ensure that you have a full understanding and
comfort level with the benefits of automation. If your company is currently using automation in its processes, you already
understand the advantages your business has gained over your competition.
In this edition we are going to discuss robotic applications: spot and MIG welding cells, material handling; pick and place,
palletizing and assembly to name a few. We will also take a look at some conveyor and sorter systems that are available.

Robotic Applications: Welding
Automated welding has improvements over manual
welding by increasing speed, quality and throughput.
Top-notch weldments are easily repeatable with robots.
Robot welding automation is also much safer and more
cost-effective. We will speak of two of the most com-
mon methods: Spot and MIG Welding.

                                                                  MIG Welding
                                                                  Gas Metal Arc Welding (GMAW) is frequently referred
                                                                  to as MIG welding. It is a commonly used, high deposi-
                                                                  tion rate welding process. The MIG welding process
                                                                  involves feeding a wire continuously toward the heated
                                                                  weld tip. It is considered a semi-automatic welding
                                                                  process. Fully automated MIG welding offers many ad-
Spot Welding                                                      Benefits of Robotic MIG Welding:
Spot welding is the most common welding application                      • Capable of all-position welding
found in the manufacturing field. Also referred to as                    • Have higher deposit rates than SMAW
resistance welding, it is used to join thin metals to-
gether or for heat-treating projects. While it is com-
                                                                         • Need less operator skill
monly used in the automotive industry to join sheet                      • Longer welds without stopping
metal frames together, the spot welding application has                  • Minimal post weld cleaning
a variety of project uses. Automated spot welding is                     • Produce high quality welds
quick, effective, precise and a economic solution.

Benefits of Robotic Spot Welding Automation:
       • Consistency of quality welds                                What’s Inside:
       • Repeatability                                                            • Material Handling
       • Greater Cycle Speed                                                      • Conveyor and Sorter Systems
       • Reduction of costs                                                       • Custom Design
       • Safer Workplace                                                          • Editor’s Corner
       • More movement flexibility
                                                                           Quigg International
                                                                         Industrial Automation

Robotic Applications: Material Handling
Material handling robots are used to move, feed or dis-
engage parts or tools to or from a location, or to trans-
fer parts from one machine to another. A variation of a
material handling robot is used to build and unload
units on a pallet. Manufacturing companies throughout
the world are implementing material handling robots
because they are faster, more accurate, efficient and
they offer unmatched quality and repeatability.

Some of the Material Handling Processes are:

    •   Pick and Place        •   Machine Loading
    •   Dispensing            •   Assembly
    •   Palletizing           •   Material Removal
    •   Part Transfer         •   Painting
                                                              A robot control system with a built-in palletizing function
                                                              makes it possible to load and unload an object without
                                                              spending a lot of time on teaching. Robotic work cells
                                                              can be integrated towards any project. With current
                                                              advancements in end of arm tooling (EOAT), robot pal-
                                                              letizing work cells have been introduced to many differ-
                                                              ent manufacturing areas.

                                                              Robotic Palletizer technology is quickly growing in
                                                              popularity for its labor and injury saving attributes. Ro-
                                                              botic Palletizers often serve multiple inbound conveyor
                                                              lanes and are flexible in their pallet build pattern varia-
                                                              tions. Most often found in higher volume applications
                                                              where pallet load qualities are shipped.

                                                              Parts Transfer / Machine Loading
                                                              Part transferring was once done entirely by hand. It
Pick and Place / Dispensing                                   was tedious, exacting work for workers. Robots are
                                                              changing this part of production. Part transfer is faster,
Pick and place robot work cells are among the most            more cost-effective, and efficient with customized ro-
popular material handling systems. They provide de-           bots. Robots do not experience fatigue, or strain. They
pendable solutions for production lines. Pick and place       work at the same rate, all the time, which increases
robot work cells perform tedious, repetitive tasks with       production and accuracy.
ease, speed and accuracy.                                     Recent technological advancements in robot end of
                                                              arm tooling (EOAT) and vision systems are making
Palletizing / Packaging                                       robotic part transferring even more attractive to compa-
Palletizing refers to the operation of loading an object
such as a corrugated carton onto a pallet or other de-        Robotic Assembly
vice in a defined pattern. Depalletizing refers to the op-
eration of unloading the loaded object in the reverse         Assembly robots have expanded production capabili-
pattern.                                                      ties in the manufacturing world. The assembly process
Many factories, food processing plants and palletizing        is faster, more efficient and precise than ever before.
plants have automated their application with a palletiz-      Robots have saved workers from tedious and dull as-
ing robot. Robotic palletizing technology increases pro-      sembly line jobs, and increased production and savings
ductivity and profitability. Robotic palletizing systems      in the process. Automated systems provide precise,
allow for more flexibility to run products for longer peri-   exact assembly performance. Many of them are
ods of time.                                                  equipped with vision technology to aid in production.
                                                                              Quigg International
                                                                            Industrial Automation

                                                                Grinding and Deburring
                                                                Manual grinding and deburring is tough, dirty, and
                                                                noisy work. The metal dust produced is harmful to a
                                                                worker's eyes and lungs. Grinding and deburring ro-
                                                                bots remove excess material from the surface of ma-
                                                                chined parts/products quickly and efficiently. The proc-
                                                                ess is perfected through automation. The end result is
                                                                that the finished product is more accurate and consis-

                                                                Robot Drilling provides the best alternative to the tax-
                                                                ing, and often dangerous work of manual drilling. Again
                                                                a huge improvement in accuracy, repeatability, and
Material Removal                                                speed along with increased productivity and savings.
Applications that perfect product surfaces can range            Painting
from harsh, abrasive methods, such as what is used to
smooth steel; to precise, careful spot removal tech-            Industrial painting robots transform application appear-
niques for parts as small as jewelry.                           ance, consistency and throughput. A painting robot
                                                                system increases material savings through greater ap-
Grinding, deburring, drilling, sanding, polishing and           plication efficiency. The precision of a robotic system
painting are common elements of most manufacturing              can generate savings of 20% to 30% in paint or other
processes.                                                      coatings material costs.

                The Advantages of Using Robots in your manufacturing processes:
                                Robots allow for faster cycle times which will increase your throughput, and
                                in turn increase your capacity.
                                Robots provide the opportunity to remove workers from repetitious and/or
                                dangerous work.
                                Robots perform with great accuracy. They don’t make mistakes so your
          Quality / Precision
                                company doesn't end up wasting time or materials.
                                Robots are able to repeat their tasks again and again without tiring or re-
                                quiring a break. They are never late for work or call in sick.
                                Robots can work 24 hours a day, seven days a week without stopping or
                                tiring. All they require is some routine maintenance, just like your car.
                                Robots are reprogrammable and tooling can be interchanged to provide for
                                multiple applications.
                                Affordable robotics are available, your ROI can be weeks to a few months,
                                depending on your application.
                                                                         Quigg International
                                                                       Industrial Automation
                                                            Electrical Motor Roller Drive Conveyor
                                                            This relatively new style uses specialty drive rollers with
                                                            self-contained motor. Usually one drive roller powers
                                                            several neighboring passive rollers by the means of
                                                            connecting belts forming and independent drive
                                                            zone. This conveyor is extremely well suited where
                                                            noise, power consumption and changes to conveyor
                                                            layout are important. Self contained motor controllers
                                                            are often built within the conveyor frames providing an
                                                            almost plug and play modularity to the sections.

                                                            Belt Conveyor Systems
                                                            Some examples of belt conveyors systems:

                                                            Belt Conveyor
Roller Conveyor Systems                                     This general class of conveyor has many applications
Some examples of roller conveyor systems:                   in bulk handling and heavy industries. For lighter pack-
                                                            age and tote handling, this conveyor is generally used
Live Roller Conveyor                                        where contact slipping is of concern. Examples of this
                                                            are incline and decline conveyors and metering belts
This general class of conveyor is probably the most         that tightly control gaps and involve accelerations on
common style found in manufacturing and distribution        the loads. Although a simpler class compared to roller
environments. Usually, live roller conveyors use human      conveyor, many variations are common.
power or gravity to assist in the movement of items.
                                                            Slider Bed Conveyor
Belt Driven Live Roller Conveyor (BDLR)
                                                            A class of belt conveyor that drives a continuous woven
Driven by a common flat belt running underneath the         flat bed over a flat (usually) metal surface. Very eco-
rollers, traditionally in fairly long straight runs. This   nomical in construction this conveyor is well suited to
style is generally used in transportation in warehouses     medium length transport applications without accumu-
where divert and accumulation requirements are mini-        lation requirements.
mal. Variations of accumulation styles are available
and diverters are usually external and independently        Belt on Roller Conveyor
                                                            In the same class as the Slider Bed, this belt conveyor
Chain Driven Live Roller Conveyor (CDLR)                    runs on a bed of passive rollers that reduce friction and
                                                            power requirements. Slightly more costly than the
Driven by a roller chain that closely couples the rollers   Slider Bed, it is usually used to accommodate heavier
mechanically, one to another. Traditionally used with       loads or greater distances with a given horsepower
heavy loads where very positive drive is required such      class of motor.
as pallet conveyance or handling metal components in
mass.                                                       Conveyor Belt Curves
Lineshaft Conveyor                                          A special shaped belt and tapered drive rollers allow a
                                                            continuous flat surface around (usually) 90 degree
Individual rollers are driven by twisted conveyor belts     curves. Typically found in applications where loads of
coupled to a drive shaft that runs down the length of       size variations would make roller curves impractical.
the conveyor frame, typically under slung to one
side. This is very flexible style of conveyor known for     Spiral Belt Curve
it’s economies in motors required, accumulation zone
capability and slave driven divert mechanisms. Very         A very specialized class of belt curve that forms a con-
well suited to manufacturing work cell automation and       tinuous helix shape for close quarter inclines or de-
divert intensive applications in warehouse and distribu-    clines. This method saves a lot of floor space for eleva-
tion environments.                                          tion changes.
                                                                            Quigg International
                                                                          Industrial Automation

Sorters                                                        Custom Design
This general class of equipment is typically an array of       Quigg International can design and produce robotic
closely coupled; high density diverters used to sort           systems that provide the latest in metal cutting tech-
cartons / totes to specific transportation lanes / chutes      niques, automatic part transfer and robotic load/unload
for consolidation and/or shipping functions. There are         of weld cells, laser and assembly systems.
many different styles within this product class. Here are
a just a few for general information.                          Our multi-station robotic systems can offer significant
                                                               cost savings when it comes to; reducing floor space,
Popup wheel                                                    faster cycle times and reducing the number of opera-
                                                               tors required for production.
This class of sorter is usually based around a Slider
Bed conveyor with diverters comprised of arrays of             Quigg International can design a complete range of
wheels that drive the load off onto a spur when actu-          welding systems; from semi-automatic single station
ated to contact the bottom of the load, slightly above         machines to fully automated multi-cell lines for welding
the belts surface.                                             multiple components including automatic part transfer.
                                                               Systems include dedicated and robotic systems for;
Steerable wheel                                                MIG & resistance welding, laser cutting & welding and
                                                               ultrasonic systems for plastic welding.
Similar to Popup wheel, the diverter wheels variably
skew allowing a greater degree of control and the op-          We have experience integrating lasers and robots for;
portunity for diverts left and right at a diverter location.   laser cutting stamped and hydroformed components,
                                                               as well as laser marking devices. Many of the cutting
Narrow Belt Sorter                                             systems utilize robotic YAG laser cells.

Using the same principles as the wheel Popup and               Quigg International can design and produce a com-
Steerable wheel sorters, transport down the length of          plete range of assembly systems; from semi-automatic
the sorter is performed by an array of narrow, evenly          single stations to fully automated multi-cell lines with
spaced belts. This allows for a clean division between         automatic part transfer.
transport and diverter.
                                                               If the application calls for it, our assembly systems can
Small Item Sorters                                             be equipped with; transfer & conveyor systems, vision
                                                               and inspection stations, programmable pick & place
Using the same technologies as their bigger cousins,           arms, robotic work cells & systems and even special
the small item sorters are in a class of their                 purpose tooling.
own. These machines are well suited to E-distribution
applications of like sized small items, such as video          Quigg International can be your one source for all
cassettes and CDs. Many styles are available newer             your automation needs.
innovations are using micro-belt technologies with very
high rate capabilities.                                         Editors Corner:
Shoe (or Slat) Sorters                                          Thank you for taking the time to look over our news-
                                                                letter. We trust you will find the information provided
Used in high rate carton sorting applications such as           useful and informative.
loading dock areas of large distribution centers Named
after the sliding ‘pucks’ that guide loads off the main         All Quigg International newsletters can be found on
sorter, typically down conveyor lanes or chutes, these          our website by following the link:
machines are the fastest in their class.
                                                                Your feedback on our content and any suggestions
                                                                to improve our newsletter are always welcomed.

                                                                Please contact us at:

                                                                Tel: 1.519.737.0700
                                                                Fax: 1.519.737.0400

To top