Case studies from specific projects include: -------------------------------- ASM Industries Leading Confectionery Manufacturer Cadbury Schweppes

ASM INDUSTRIES

Robots Perform Quality Control Role

A.S.M. Industries manufactures products for the Automotive Industry, including car alarm components exported to European markets by it's customer Robert Bosch (Australia) Pty Ltd, for use by companies such as Opel, Volvo and Audi. To assist in this program, A.S.M. Industries are using a robot at their Clayton, Victoria manufacturing site to ensure the highest possible quality standards are maintained in its manufacturing process.

As a leader in plastic component manufacturing for many industries including the demanding automotive industry, A.S.M. Industries perform rigorous testing procedures under their ISO9002 quality program. Utilising robot technology as an integral part of this process ensures testing procedures are duplicated exactly each and every time they are performed. A.S.M. Industries recognise this as one of the primary benefits with robotics; robots perform exactly the same role over and over again without the variables introduced by operators.

With the prohibitive price of dedicated testing machines, A.S.M. Industries approached Robotic Automation Pty Ltd with an idea to work with them to incorporate robot technology into the quality control and testing procedure for a car alarm siren they manufacture. With production which could exceed 400,000 units a year, A.S.M. Industries required a high speed, flexible solution.

The final solution involved a Motoman SV3 robot being interfaced with a personal computer, a barcode label printer, an ultrasonic welder, a leak test instrument, a sound level meter and barcode readers.

How it Works
An operator loads 2 components into a fixture where they are clamped and moved into the robot cell. An ultrasonic welder is used to join the plastic components together. When this is completed, the robot picks up the unit and moves it to the barcode printer where the PC generated label is applied. The siren is then moved by the robot to a Leuze electronic barcode reader for verification.

If no label is detected, the siren is placed into the "no label" reject shute. If the label is detected, the siren is placed into the fixture, clamped and leak tested. Because the leak tester has the longest cycle, Robotic Automation have programmed the Motoman robot to return to the start and begin the process again with new components. This ensures production occurs as rapidly as possible and all machinery is constantly in use.

If the car alarm siren passes the leak test, it then undergoes a sound test. Providing the siren passes both tests, it is deemed to have successfully passed the quality control procedure and is placed in a shute and presented to the operator. If the unit fails any of these critical tests, the unit is stamped with an "R" and placed in a reject shute.

Specially Written Software
The data acquisition software used in this process was written by Robotic Automation. It combines the Visual Operator Interface software (VOI) and the automated process. One operator can monitor the entire production process. A.S.M. Industries have been able to drastically reduce their cycle time from approximately 3 minutes per siren to 30 seconds per siren through the use of robotics and associated technology. The eventual aim is to reduce cycle time to around 20 seconds per unit.

Robotic Automation are leaders in robotic technology. Through their close association with Motoman Robotics, Robotic Automation offer a complete turnkey service from their extensive resources; site evaluation, design, supply of all automation equipment, installation, commissioning, operator training, and after sales support.

LEADING CONFECTIONERY MANUFACTURER

A leading confectionery manufacturer in Sydney is using a Motoman SV3 robot from Robotic Automation to pick and place individual packets of confectionery.

Located at the end of the production line, the Motoman SV3 picks up 12 packets of sweets at a time and places them into a carton for shipping and display. With its small payload and compact size, the SV3 is ideal for handling delicate lightweight products such as a packet of sweets.

To ensure the product is not damaged, Robotic Automation designed and built a gripper for the robot specifically suited to the customer's requirements with pneumatic suction cups.

Cleanliness Critical
The Motoman SV3 is ideal for high-speed "pick and place" work in the food industry where cleanliness and hygiene are critical. The profile of the robot is smooth, making it difficult for particles to adhere to the surface. Also available is the Motoman SV035 which is fully water-resistant and can be hosed down for cleaning and the removal of raw material or residue. The SV035 complies with IP65 industry standards.

The standard motion pattern on the Motoman SV3 can be run in only 0.7s for a 300 mm stroke, the highest speed in its class. This represents a dramatic decrease in handling time and is a new speed record for perpendicularly articulated robots.

Depending on the product, the Motoman SV3 robot can be used for a number of activities. It is ideal for automating case packing (in this case, packets of sweets), tray loading and food handling.

The SV3 can be used in conjunction with the Motoman high-speed vision sensor system that will aid efficiency in processes where products come down a conveyor at random. Once the approaching product is seen, the robot will be prompted into action.

The Motoman SV3 comes complete with a Yasnac XRC controller and has the CE marking. The volume of this unit has been halved compared to previous controllers giving it a smaller footprint. To aid ease of operation, users are able to assign function keys to commonly used commands to make work even faster.

Robotic Automation Pty Ltd offers the complete range of Motoman robots, including the SV3, and provides advice, technical support, service and spare parts. Robotic Automation has many years experience supplying turnkey systems to Australian industry.

HANDLING OF CHOCOLATE

Cadbury's was established in Australia in 1922 when it opened its first factory in Claremont Tasmania. It is now part of the Cadbury Schweppes global company which manufactures and distributes confectionery in approximately 200 countries worldwide with the plant in Ringwood, Victoria producing the Chocolate Bars, Easter eggs and Seasonal Products for Australia and the Asia Pacific region.

Cadbury recently installed a Motoman SV3 Robot for use in the manufacture of the Yowie product.

		According to Richard Taylor Cadbury's Project Manager, "profitability has been improved and the risk of repetitive strain has been removed as a result of the installation". Mr. Taylor went on to say "Evaluation of Cadbury's requirements covered various methods including Cartesian robots however the selection of 6 axis robot was justified because its increased dexterity, reduced tooling costs and allowed more flexibility in the design of the work station. Vision systems were not required because control of the product is maintained the whole way through the process."

"Once it was determined that a 6 axis robot would be used the project was carried out in house. The selection of the Motoman robot was made on the basis of cycle speed, compact design and cost. The gripper design was determined to be the greatest area of technical risk, this risk was successfully minimised by including it in Robotic Automations supply scope of supply."

Cadbury's have just installed a Robotic Easter egg de-moulder just prior to foiling machines; this uses two Motoman UP 20 robots. The Motoman Robot features pre-assigned I/O and made the electrical installation very easy.

Cadbury's started working with Robotic Automation in 1998 and will continue to use their service and spare parts support and would certainly consider their range of products for plant automation projects in the future.

Robotic Automation Pty Ltd are the exclusive distributors for Motoman Robots which can be used for a variety of applications including arc welding, spot welding, palletising, materials and machine tending.

Robotic Automation offers consulting advise to clients wishing to develop applications, sales, service, and preventative maintenance contracts supported through its extensive network of National offices.