How to Answer 5 Tough Questions About Your Automation ...

Share this article

Click here to get more.

In the rapidly evolving field of robotic automation, success hinges on meticulous attention to detail. After outlining your needs and thoroughly documenting your processes, you can turn your focus towards tailoring the automation mechanism to fit your specific requirements. For those in leadership roles within manufacturing, this often involves making crucial yet small decisions regarding component movement, selecting suitable end-of-arm tooling, and other essential factors. Below, we delve into five demanding questions that you may face during the selection of automation components, along with effective strategies for addressing them.

Do you require remote vision capabilities?

Modern robotic systems possess not only incredible operational capabilities but can also incorporate optical technologies to enhance their visual functionality, significantly boosting precision throughout various stages of the automated process. While not every factory design or automation system necessitates visual technology, certain scenarios benefit from it:

• Parts retrieval: Challenges like limited space may hinder the development of a precise parts-feeding arrangement. In such instances, machines equipped with vision systems can effectively pick up components and guide them further along the production line.
• Measurement: Are there aspects of your process that necessitate measurement?
• Scanning: Vision solutions empower robots to scan barcodes, labels, and other essential markers integrated into the manufacturing pipeline.
• Conducting inspections: Visual technology can significantly enhance quality assurance by involving robots in inspection tasks, allowing them to assess surface quality, packaging integrity, component reliability, final placement accuracy, and defect detection.

How do different feeder types compare in the market?

Transporting components from point A to point B is the vital rhythm of an efficient automated workflow. Referred to as “parts presentation” in the manufacturing sector, this phase dictates how individual items reach your robotic assembly system. The choice of equipment and the sequence at which components are introduced can profoundly influence productivity metrics, particularly speed. While designing your setup, it's essential to consider the various feeder types available based on your production needs:

• Flex feeders: Designed to accommodate a variety of parts, flex feeders utilize vision-guided systems that allow robots to select components during the assembly phase.
• Linear feeders: Functioning akin to conveyor belts, linear feeders utilize vibratory technology to facilitate movement, transporting parts towards the robotic arms.
• Bowl feeders: Ideal for more standardized component handling, these vibratory feeders can manage diverse materials, with centrifugal versions available for high-speed applications requiring gentler handling.

How can you tailor your end-of-arm tooling?

Having decided on how components will be delivered to the robot, the next step involves assessing your requirements for end-of-arm tooling (EOAT). EOAT solutions are fundamental to the manufacturing landscape. Throughout the automation journey, you will pinpoint your specifications, including both standard and potential custom tooling needs. Custom EOAT can manifest in either specially designed tools or through unique implementation strategies within your factory. Key considerations for EOAT selection include:

• Power source: Consider whether electric, hydraulic, or pneumatic tools will suit your needs.
• Clarifying application requirements: What tasks will the tools perform? Common functions may include transporting components or relocating items within the workflow.
• Diversity of tools: The EOAT category encompasses a wide array of tools. Once you've clarified your needs, explore the various tools available to determine the ideal match.

What do you need in a base for system stability?

The base supporting your robot serves as the project's cornerstone, yet it often receives less scrutiny than it deserves. A variety of base options exist, including tables, blocks, and robotic pedestals. Some robots function seamlessly with pre-designed bases, while others necessitate tailored structures for optimal performance. When selecting a base, consider:

• Its capacity to support your robot’s weight, encompassing both machinery and maximum load.
• Its agility in sustaining the motions required by your production line without compromising stability or slowing operations.
• Requirements for features like cooling systems or surface grinding for precision applications.
• Aesthetic considerations that might require customized finishes, such as paint or lacquer.

What role does IT play in fulfilling factory standards?

Incorporating IT infrastructure into the automation journey adds another layer of complexity. It's vital to involve your IT department from the outset and throughout component selection processes. The foundational architecture plays a crucial role in securing long-term operational success. Here’s a quick checklist of factory standards to evaluate:

• What is IT's existing role in your production setup? Certain factories heavily integrate their systems, while others maintain a lighter technological footprint. Delineate the extent of IT’s involvement and how current systems will merge with new solutions.
• Are you utilizing a standardized fieldbus communication platform? Essential to smart manufacturing, these platforms allow seamless connections to various points within your robotics infrastructure.
• Are there established protocols in use? Different industries employ various protocols, with options like Ethernet/IP, ProfiNet, DeviceNet, SmartWire-DT, and Varan being common.
• Are there visual components like cameras, lasers, or processors that warrant consideration?
• How do your elements interface with your system's safety controller?
• Are there communication, compatibility, or other concerns relative to the robotic controller or broader industrial network?

Detail-oriented engagement throughout your automation undertaking might seem laborious, but it can yield substantial returns on your investment. Tailoring your automation components maximizes the effectiveness of your robotic applications, aligning with your specific demands. Today's advanced manufacturing solutions utilize vision systems, end-of-arm tooling, and feeders to accelerate production processes while ensuring that robotic setups are fortified by robust foundations and the requisite technological support.

Are you eager to discover more about robotics automation? Download Automation 101: A Step-by-Step Guide to Getting Started with Robotics today!

Rather than inquiring about the vendor's PLC or servo sales volume, ask them how many thousands of packaging machines their servos are integrated into each year.

A previously posed rhetorical question was, “What’s beneath the surface of your automation system?” An increasing number of control vendors are adopting the IEC-3 programming language standard; however, not all are equally proficient. Thorough evaluation of a control platform is crucial before any commitments concerning your packaging machinery.

This article also provides functional specification content for PLC and servo capabilities that packagers and machine manufacturers can download and include in their internal control specification documents.

Before progressing to the RFQ phase, consider these ten pre-qualifying questions to vet potential automation suppliers:

1. How do you integrate motion and logic? Is all control managed within a single processor, or do you still rely on a rack-based system?

An ideal integration entails performing motion and logic control within a singular IEC-3 compliant program on a single processor. Backplanes and multi-card arrangements tend to hinder operational efficiency.

2. Do you support and adhere to all IEC-3 programming languages?

It’s essential to respect all languages within the standard and observe best practices during programming to leverage each language’s strengths. The result is a modular and comprehensible control architecture rather than a convoluted and opaque one.

Qisheng provides professional and honest service.

3. What resources do you offer to assist machine builders in quickly developing top-tier machines? How many functions do you provide for packaging machines?

A fully open programming environment is mandatory, accompanied by a software library featuring hundreds of pre-tested software objects (IEC Function Blocks), routine scripts, and templates specifically engineered for packaging machinery.

4. What is the maximum number of servo motors that your system can control? What is the motion network update rate? How many virtual axes can be utilized?

The cutting-edge standard permits up to 99 axes per controller with a maximum network-wide update rate of 1, 2, or 4 milliseconds, not cumulative by axis. Support for an unlimited number of virtual axes should be guaranteed.

5. Are essential components like Ethernet, Sercos field buses, etc., provided as standard equipment or optional add-ons? What is necessary to access all system parameters and data?

All features should be standard. Preferred interface methods ought to include OPC server, Web server, data/message logging, digital oscilloscope, and other tools for complete control over data flowing in and out of machinery.

6. What solutions do you offer for rotating capping, filling, and labeling machinery?

Integral motor/drives are essential for enhancing rotary machines, potentially doubling output rates. These components can be strategically placed on rotating platforms to achieve precise control over capping torque, bottle plates, and dosing systems.

7. How do you implement electronic camming? Are you still using x-y tables and basic 3rd-degree polynomials? Is it possible to modify any cam segment on the fly?

Demand the use of 5th-degree polynomial cam profiles with the capability to alter cams on-the-fly. Cam profiles should not be pre-loaded into servo drives; this outdated practice hampers speed and efficiency. Cams ought to be generated mathematically in real-time by the controller.

8. What software costs should we prepare for across our engineering team? What is the number of software components each engineer must procure?

Hidden software expenses can accumulate rapidly unless you mandate the vendor’s software development environment to be available via a site license, allowing all engineers to access required tools, libraries, and templates for a fixed sum.

9. What efforts are you making to reduce cabinet space within machinery?

Are your machine cabinets becoming as large as the packaging equipment they house?

Innovative space-saving controllers and drives can decrease cabinet footprints by up to 50% compared to traditional PLCs, motion controllers, and drives.

10. How many thousands of packaging machines have you outfitted with servo systems over the past year?

This pivotal question sheds light on domain proficiency. It’s less about the sheer number of PLCs or servos sold, and more about how many thousands of packaging machines are equipped with their servo solutions on an annual basis.

Contact us to discuss your requirements for Automation Equipment Precision Parts. Our seasoned sales team is ready to assist you in identifying the best options tailored to your needs.