See how unified control for its robotics helped a consumer packaged goods firm achieve an autonomous system capable of performing complex tasks.
To become more competitive, industrial firms often begin by integrating automation and corresponding solutions into their existing production. Robots have proven highly efficient in this regard. However, due to the closed platforms used by robot manufacturers, different systems must collaborate within production environments, leading to interface problems by increasing the number of control systems in use. This complicates operations and can result in data loss.
Open mechanics eliminate interfaces and additional controls. With these solutions using unified control, the operator receives a highly integrated and autonomous system capable of performing complex tasks.
Many production areas need to address employee shortages, increase efficiency and maximize flexibility. The following case describes these challenges in packaging for consumer packaged goods, a process that often creates bottlenecks slowing down production throughput.
Figure 1. In this case study, the machine is used for sorting different goods onto several conveyors. Two wash-down autonox DELTA kinematics are positioning them on an additional conveyor feeding the packaging machine.
In the design of the mechanics, the external use of hexagon socket screws, springs, tight radii and gaps is avoided as much as possible. The upper arm gearboxes, joint and telescope bearings are (double) sealed.
Consumer Packaged Goods Sorting
In this use case, the machine is used for sorting different goods onto several conveyors with a cycle time of about 1 second per cycle. Requirements include efficiency, speed and precision. Consumers demand high-quality products at acceptable prices, putting pressure on manufacturers to streamline their production and eliminate sources of quality or downtime issues.
An additional requirement is handling consumer goods on moving conveyors, using multi-parallel kinematics with different technical specifications based on varying requirements.
First, it’s necessary to have direct contact with the products by sorting them for the first packaging machine. Based on cleaning requirements, kinematics with wipe-down (HND) and wash-down (HHD) options are available.
In this case, two wash-down autonox DELTA kinematics — HHD DELTA RL4-1200-3 kg — are positioning them on an additional conveyor feeding the packaging machine (see Figure 1). The mechanics are made of materials approved for the food industry. Coatings of any kind are generally avoided. They can be cleaned with the usual methods of the food industry. Food-grade, also FDA-compliant lubricants are used.
In the design of the mechanics, the external use of hexagon socket screws, springs, tight radii and gaps is avoided as much as possible. The upper arm gearboxes, joint and telescope bearings are (double) sealed.
After the products are packaged, they’re case packed into cardboard boxes using a standard autonox DELTA kinematic — DELTA RL4-T1-1200-3 kg (see Figure 2). The additional T-shaft offers the possibility of mechanical tool actuation with additional torque available on the tool holder used to open and close a gripper.
Figure 2. After the products are packaged, they’re case packed into cardboard boxes using a standard autonox DELTA kinematic, DELTA RL4-T1-1200-3 kg. The additional T-shaft offers the possibility of mechanical tool actuation with additional torque available on the tool holder used to open and close a gripper.
Design Software and Servo Motors
The system uses unified robot control to eliminate the need for independent robot controllers and a dedicated programming platform, and instead uses a Logix controller and the Rockwell Automation Studio 5000® automation system design software for complete system control. Further value was added by using Allen‑Bradley® Kinetix® servo motors and servo drives to maximize the performance and energy efficiency of the robot mechanics.
This optimized control architecture simplified system control, enabled new efficiencies in the design process and accelerated time-to-value for the project.
Robots were programmed using robot libraries embedded in the Studio 5000 environment, and the solution was validated within Rockwell Automation Emulate3D™ software to virtually commission the system in a digital environment before committing to the physical build stage of the project.
Multiple robot kinematics and two different packaging stages (primary and secondary packaging) are controlled using one drive family (for conveyor, robots and process devices) and one control system PLC as one machine. This makes the robots organic to the machine design in every way.
The advantages include having the same drive families throughout the machine — conveyor, robot, etc. The OEM can focus on the solution without worrying about learning and supporting different control systems for the robot and the machine.
This results in one production data system in the control system on one network, providing the customer with these benefits:
- Better synchronization of robots and surrounding devices, such as independent cart technology, because they’re all motion axis under one controller.
- One operating environment and programming system for complete system control, including integrated safety.
- Maintenance service time and stock are reduced due to using the same parts (motors and drives) for all moving parts, including the robots.
Product Focus
autonox Lean Line Mechanics
In addition to the autonox DELTA classic line from autonox Robotics, autonox Lean Line mechanics models are soon available for up to 6-kg payload. For direct integration into the machine structure, this design is also available without a head plate. The direct connection of the gearbox support to the machine frame reduces the overall height. HND Design is possible.
Lean Line mechanics require additional maintenance compared to autonox standard DELTA mechanical designs and do not have the same high range of performance options available, but they do offer a good price point with a reliable design for cost-sensitive applications.
A new feature for our Lean Line is the use of the telescopic shaft for Tool Actuation "T Shaft.” The telescopic shaft can also be used to actuate the end effector (e.g. opening/closing a product gripper). There are internal threads for mounting the end effector on the tool holder. This is useful because no media (hoses, cables, etc.) need to be routed to the end effector. The actuator, which is usually heavy, is located above the robot (on the head plate).
