PneuConnect with GRT gripper on a UR cobot. Source: PHD
PHD Inc. this month added three products to its line of grippers and accessories for industrial automation. They are intended to help robots grip large objects, make positioning and programming easy for maximum efficiency, and facilitate machine tending. PHD’s products are designed to work with collaborative robot arms, or cobots, from Universal Robots A/S.
Fort Wayne, In.-based PHD said it sells grippers, linear slides, and the widest range of long-life, robust actuators in the industry. It also offers engineering software and Internet-based tools to save design time, support from factory-trained application and industry specialists, and rapid product delivery.
PHD adds jaw-travel option to GRR line
The company has added a 300mm (11.81 in.) jaw-travel model of its Series GRR high-capacity pneumatic grippers. These parallel grippers are designed to provide high grip force, five long-jaw travels, and high loads.
Because the Guardian grippers can withstand high impact and shock loads, they are suitable for applications such as small engine block manufacturing, automotive wheel-rim manufacturing, and foundry applications, said PHD.
Also available is the Series EGRR high-capacity electric parallel grippers, which offer many of the same benefits as the pneumatic design.
Pneu-Connect X2 with dual grippers available
PHD also announced the release of Pneu-Connext X2 kits with dual grippers. They can be mounted to UR cobots for maximum efficiency in automation performance.
The Pneu-Connect X2 includes PHD’s Freedrive feature, which interfaces with UR cobots for easy positioning and programming. The kits come in the following standard combinations:
Transition plates connect UR directly to linear actuator
PHD’s transition plate allows a Universal Robot arm to be directly attached to the new PHD Series ESU electric belt-driven linear actuator. The company said it offers a transition plate for each size of UR arm, “taking machine tending to a whole new level.”
This transition plate provides a seventh axis for UR arms with the ESU linear actuator. Source: PHD
With a cataloged stroke of up to 5500mm (216.53 in.), users can increase the working area of a UR10 arm by 10 times.
Toolcraft Inc., a small precision machining shop in Seattle, makes parts for industries including aerospace, defense, and medical. It needed help tending its CNC machine and ultimately turned to Universal Robots A/S’s e-Series collaborative robots.
Faced with labor shortages and a demanding manufacturing task, Toolcraft assessed its alternatives and worked with an integrator to apply a UR5e cobot to its process.
Challenge
Toolcraft needed to automate a three-step task to keep up with production demands, especially when a large medical device required it to add a third shift for round-the-clock operations. Finding workers is difficult in a region with 3% unemployment.
“Nobody wants to run on third shift around here,” said Steve Wittenberg, director of operations at Toolcraft. “When you put an ad out, you’re not getting very many responses.”
The company initially looked at traditional industrial robots but realized that it would have to add costly safety infrastructure.
“If we looked at just the robot hardware alone, that appeared to be a more cost-effective solution,” Wittenberg said. “But once we started factoring in the savings on not having to erect a safety cage – and the time saved on the ease of use, avoiding a lot of complex programming – Universal Robots ended up being the right solution.”
Solution
Toolcraft discussed its need for loading a medical device part into a CNC machine for multi-threading with Rapid Design Solutions, a certified systems integrator for UR cobots.
“When we heard that the repeatability of the UR5e was down to 30 microns, we were very excited,” said Troy Ojalehto, owner of Rapid Design Solutions. “That really competes in the same space as traditional industrial robots, so that was huge for us. I have not seen other cobots handling this level of precision with multi-op parts like this, with raw stock going in and completed precision parts coming out.”
Thanks to its force-feedback feature, the UR5e is able to make the part fit tightly in the CNC fixturing. “Using the force motion with freedom in the X,Y and rotational Z axes, we can force the part in there, and wiggle it, and program that compliance very easily to enable basically a human touch with the robot,” he said.
The UR+ program, which certifies that accessories such as grippers, vision systems, and software will work with UR cobots, helped speed up integration.
“For this application, we chose a Pneu-Connect pneumatic gripper,” said Ojalehtos. “A big factor is that it’s UR+ certified, which means it works with Universal right out of the box, with all gripper software integrated directly on the UR teach pendant, eliminating the need to do any script coding.”
Toolcraft chose the UR+ certified PneuConnect gripper, which works seamlessly with UR’s teach pendant. Source: Universal Robotics
Results at Toolcraft
“Some of the benefits we’ve seen right off were a significant production increase,” said Wittenberg. “We were able to staff that third shift and went from producing 255 parts a week to 370 parts per week. Along with that, we’re able to finish our year’s production seven weeks sooner, thus freeing up that machine to produce parts on other jobs.”
After six months, Toolcraft saw costs decline by 23%, and it now expects a return on investment on the cobot arm at about 12 months.
“We’re going to be able to be more competitive on a lot of the long-term work that we have,” Wittenberg said.
Since the UR5e cobot only tends parts for six minutes out of a 56-minute cycle, a Toolcraft engineer added a part rinsing and cleaning station after using Universal Robots‘ online training.
“After our automation engineer took the online UR Academy, he spent a few hours with the integrator and was able to add that station to the cobot cycle with no external help otherwise,” said Wittenberg. Universal Robots’ simulator also allowed Toolcraft to program most of the additional tasks without taking the cobot offline.
After certified systems integrator Troy Ojalehto (right) developed the initial application, Toolcraft automation engineer Brian Laulainen (left) was able to handle daily operations and build add-ons for the UR5e after training through the UR Academy. Source: Universal Robots
In addition, the company was easily able to use Universal Robots‘ I/O interfaces to control the pneumatic fixture and door actuators. “This greatly reduces the need for CNC wiring and preserves all the CNC’s standard safety functions,” Ojalehto said.
The installation has been so successful that Toolcraft is planning to install one cobot every year. “The fact that our own automation engineer is now able to go in and troubleshoot anything that comes up is going to be key in us meeting this goal,” Wittenberg said.
Toolcraft plans to automate tending a horizontal mill next. “That’s a potential challenge because of the mills using rotary tombstones that are swapped in and out of the milling machine, which creates some difficulties with fixturing,” said Wittenberg. “But we’re confident we can solve those using a Universal Robot and some innovation in fixturing.”
New Scale Robotics (NSR) has announced the first multi-tool mounting system for Universal Robots (UR) e-Series cobots. The NSR-MTM-3-URe Multi-Tool Mount (NSR-MTM) allows users to mount and control up to three grippers or other tools on one UR e-Series cobot.
The NSR-MTM System allows users to quickly set up and perform multiple processes with one robot. Benefits include:
Higher throughput in small part handling and inspection tasks.
Fewer large moves, for reduced cycle times without compromising safety.
The ability to automate more processes with fewer robots.
The NSR-MTM System includes both hardware and software. With low mass and small size, the hardware is compatible with UR’s smallest UR3e cobot. The integrated Freedrive button enables one-handed positioning to teach and set positions. The software enables fast setup and easy programming of up to three devices in one user interface on the UR teach pendant.
New Scale Robotics NSR-MTM-3-URe Multi-Tool Mount. | Credit: New Scale Robotics
NSR Devices Software is a new URCaps plugin for UR e-Series robots. Users can quickly add multiple tools to the single user interface, build tool processes with a few clicks, and run complex automation or inline inspection programs with ease. Other smart features include dynamic adjustment of tool center of gravity depending on mass of object picked.
The MTM hardware mounts to the UR robot tool flange with four screws and one connector to the internal tool port. Up to three tools are mounted on the MTM faces using the standard ISO 9409-1-50-4-M6 interfaces and M8 round connector. The MTM mount uses power and RS485 signals from the robot’s internal cables and slip rings. No external cables are required.
Applications include small part picking, movement, measurement, data logging, sorting and assembly. Used with the small and precise grippers from New Scale Robotics, the NSR-MTM System allows increased productivity from multiple tools while still fitting in the tightest spaces.
NSR Devices Software is a new URCaps plugin for UR e-Series robots. | Credit: New Scale Robotics
Universal Robots is opening 50 Authorized Training Centers, 13 of which will be located in North America. | Credit: Universal Robots
Universal Robots (UR) is launching Authorized Training Centers (ATCs) that offer classes spanning basic to advanced programming of UR cobots. UR is planning 50 fully authorized ATCs worldwide, 13 of which will be in North America. The first few ATCs in the U.S. have already been authorized and are now offered by the following UR sales partners:
Advanced Control Solutions in Marietta, Ga.
HTE Technologies in St. Louis, Missouri and Lenexa, Kansas
Ralph W. Earl Company in Syracuse, New York
Applied Controls in Malvern, Pa.
In addition to the ATCs hosted by UR partners, four training centers are also opening at UR’s offices in Ann Arbor, MI, Irving, TX, Garden City, NY, and Irvine, CA.
UR’s certified trainers will conduct training modules that cover a range of core and advanced cobot programming skills, including cobot scripting, industrial communication, and interface usage. Small class sizes with student-centered objectives and hands-on practice with UR robots ensure that participants come away with valuable skills they can apply immediately in their workplace.
For class schedules and more information, visit the UR Academy site. The modules of the ATC program include:
Core: For any user of a UR cobot who has completed the online modules. Covers safety set-up, basic applications and flexible redeployment.
Advanced: For cobot users, technical sales people, and integrators with a practical need to optimize applications or find new ways of deploying UR cobots. Covers scripting, advanced uses of force control and TCP, conveyor tracking and performance review.
Industrial Communication: For users and developers who need to integrate cobots with third-party devices. Covers modbus TCP, FTP server, dashboard server, socket communication, Ethernet/IP and Profinet.
Interfaces: For users and developers who need in-depth knowledge on how to interface with UR cobots using script interfaces. Covers UR scripting, socket communication, client interfaces (port 30001-30003), real time data exchange and XML/RPC.
Service & Troubleshooting: For users, technicians, and engineers wanting/needing a better understanding of the mechanical hardware used by UR cobots, how to diagnose issues and resolve them. Covers the configuration of the cobot arm, controller, and safety system as well as preventative maintenance, system troubleshooting, and replacement of parts.
UR’s certified trainers will conduct training modules that cover a range of core and advanced cobot programming skills, including cobot scripting, industrial communication, and interface usage. | Credit: Universal Robots
“Now, current and potential customers can get in-person training, customizing their specific applications and needs,” said Stuart Shepherd, Regional sales director of Universal Robots’ Americas division. “Not only are our partners excited about this opportunity, they’re virtually lining up to be the next rollout.”
“From a business perspective, being able to offer this type of training also improves our place in the market, ensuring that current and potential customers start to rely on us as automation experts,” said Cale Harbour, Vice President of Product Marketing at Advanced Control Solutions. “As our customers build their knowledge, they can deploy the technology faster and see the benefits to their production – and their bottom line – quicker. It’s a win-win for everybody involved.”
“Using this approach, we’ve expanded our role as supplier to assist with the application process as well,” said Marv Dixon, vice president of business development and sales, HTE Technologies. “The Training Center has also provided us with the perfect scenario in which we can introduce other products that our customers might not have otherwise considered, such as grippers and conveyors. With the Authorized Training Center distinction, we’ve become a resource that our customers can count on for up-to-date, accessible training and support.”
What makes a robotics cluster successful? Proximity to university research and talent, government support of entrepreneurship, and a focus on industry end users are all important. Around the world, regions have proclaimed initiatives to become “the next Silicon Valley.” However, there have been relatively few metrics to describe robotics hubs — until now.
This week, Odense Robotics in Denmark released a report on the economic returns generated by its member companies. Both the amount of exports and the number of employees have increased by about 50 percent, according to Mikkel Christoffersen, business manager at Odense Robotics.
At the same time, the report is realistic about the ongoing challenges facing every robotics cluster, including finding qualified job candidates. As locales from India to Israel and Canada to China look to stimulate innovation, they should look at their own mixes of people, partnerships, and economic performance.
Membership and money
The Odense robotics cluster currently has 129 member companies and more than 10 research and educational institutions. That’s up from 85 in 2015 and comparable with Massachusetts, which is home to more than 150 robotics companies. The Massachusetts Robotics Cluster said it had 122 members as of 2016.
Silicon Valley Robotics says it has supported 325 robot startups, and “Roboburgh” in Pittsburgh includes more than 50 organizations..
In terms of economic performance, the Odense robotics cluster had 763 million euros ($866.3 million U.S.) in turnover, or revenue, in 2017. It expects another 20 percent increase by 2021.
Odense has been friendly to startups, with 64 founded since 2010. The Odense Robotics StartUp Hub has helped to launch 15 companies. Seventy companies, or 54 percent, of those in the Odense area have fewer than 10 employees.
Total investments in the Danish robotics cluster have risen from 322 million euros ($365.6 million) in 2015 to 750 million euros ($851.7 million) last year, with 42 percent coming from investors rather than public funding or loans.
Source: Odense Robotics
In addition, 71 local companies were robotics producers, up from 58 in 2017. The next largest category was integrators at 23. The region also boasted 509 million euros ($577.9 million) in exports in 2017, and 66 percent of its members expect to begin exports.
Market focus
The Odense Robotics report notes that a third of its member companies work with collaborative and mobile robots, representing its focus on manufacturing and supply chain customers. Those are both areas of especially rapid growth in the wider robotics ecosystem.
The global collaborative robotics market will experience a compound annual growth rate (CAGR) of 49.8 percent between 2016 and 2025, compared with a CAGR of 12.1 percent for industrial robots, predicts ABI Research. Demand from small and midsize enterprises will lead revenues to exceed $1.23 billion in 2025, said ABI.
Both Universal Robots and MiR have broadened their international reach, thanks to ownership by Teradyne Inc. in North Reading, Mass.
Robotics cluster must address talent shortage
Odense Robotics said that its robotics cluster employs 3,600 people today and expects that figure to rise to 4,900 by next year. In comparison, the Massachusetts robotics cluster employed about 4,700 people in 2016.
The Danish robotics cluster is a significant employer. Source: Odense Robotics
Even as the numbers of people grow at larger robotics companies (with 50 or more employees) or abroad, businesses in southern Denmark have to look far afield to meet their staffing needs. More than a third, or 39 percent, said they expect to hire from outside of Denmark, and 78 percent said that finding qualified recruits is the biggest barrier to growth.
The average age of employees in the Odense robotics cluster reflects experience, as well as difficulty recruiting. Fifty-five percent of them are age 40 to 60, while only 18 percent are under 30.
This reflects a larger problem for robotics developers and vendors. Even with STEM (science, technology, engineering, and mathematics) programs and attention paid to education, the demand for hardware and software engineers worldwide outstrips the available pool.
The University of Southern Denmark (SDU) is working to address this. It has increased admissions for its bachelor’s degrees in engineering and science and master’s of science programs from 930 in 2015 to 1,235 last year. The university also launched a bachelor’s in engineering for robot systems, admitting 150 students since 2017.
The Danish Technological Institute is expanding its facilities in Odense this year. Source: DTI
Another positive development that other robotics clusters can learn from Odense is that 41 percent of workers at robotics firms there went to vocational schools rather than universities.
Partnerships and prospects
Close collaboration with research institutions, fellow robotics cluster members, and international companies has helped the Odense hub grow. Seventy eight percent of cluster members collaborate among themselves, according to the report. Also, 38 percent collaborate with more than 10 companies.
The Odense robotics cluster grew out of a partnership between shipping giant Maersk A/S and SDU. The Maersk Mc-Kinney Moller Institute at SDU continues to conduct research into robotics, artificial intelligence, and systems for healthcare and the energy industry. It recently added aerial drones, soft robotics, and virtual reality to its portfolio.
Last year, the institute invested 13.4 million euros ($15.22 million) in an Industry 4.0 laboratory, and an SDU team won in the industrial robot category at the World Robot Summit Challenge in Japan.
Examples such as Universal Robots and MiR, as well as Denmark’s central position in Northern Europe, are encouraging companies to look for partners. Collaborating with companies inside and outside the Odense robotics cluster is a top priority of members, with 98 percent planning to make it a strategic focus in the next three years.
It’s only through collective action around robotics clusters that smart regions, large and small, can find their niches, build talent, and maximize the returns on their investments.
Editor’s note: A panel at the Robotics Summit & Expo in Boston on June 5 and 6, 2019, will feature speakers from different robotics clusters. Register now to attend.
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