Boosting Complex Assembly by Combining Robot Dexterity with Mechanical Positioning

From left to right: The FANUC LR Mate 200 iD, the KUKA KR QUANTEC, and ABB’s IRB 6700. | Source: FANUC, KUKA, ABB Robotics

Industry experts anticipate significant growth in robotics, driven by continuous disruptive advancements. While automation remains the primary objective, specialists increasingly emphasize the critical role of mechanical positioning in determining a machine’s mobility, operational range, and speed.

A more comprehensive consideration of these characteristics can significantly enhance efficiency in automated assembly processes.

How precision positioning and components enhance robotics

Precise positioning is fundamental to robotic success, defining both its capabilities and constraints. Every robot operates within a fixed reach, irrespective of the power or flexibility of its internal components.

Each machine is both constrained and enabled by its mechanical systems, including joints and actuators. Furthermore, advanced positioning systems allow every component to function at peak performance, making these implementations indispensable for modern production.

Linear transfer systems

Linear transfer systems extend a robot’s effective range of motion. These systems, including linear and robot transfer units, facilitate smooth movement along a designated track. Utilizing such mechanisms to diversify movement enables large-scale projects, particularly in aerospace and defense, to be largely executed with robotic assistance. Unlike stationary robots, mobile models can navigate massive assemblies and perform multiple tasks with greater ease. Leading models now feature seventh-axis mobility and rapid deployment capabilities.

Rotary index tables

Rotary index tables are essential components that enhance precision and speed in repetitive processes. Integrated into robots, they enable rapid rotational movement during assembly. These tables amplify equipment capabilities by allowing robots to perform multiple tasks simultaneously, such as assembly, packing, and quality control.

Advanced workpiece positioners

Multi-axis workpiece positioners allow robots to move in various orientations rather than being fixed to a single plate or pedestal. If machinery can rotate beyond its arm’s range or approach an assembly at an angle, it can handle more complex assignments.

In industries like aerospace and automotive, where parts often feature unusual shapes and geometries, robots can navigate space more effectively and take on tasks that would otherwise require manual labor.

Vision-based positioning and compensation

Various factors, including software and peripherals like sensors and cameras, dictate a robot’s movement. Vision-based mechanisms are crucial for enabling real-time responsiveness in equipment.

If a sensor detects an obstacle, the robot can adjust its position accordingly. Over time, repeated adjustments may lead to broader misalignments, but technicians can leverage management systems and software controls to regularly review these metrics and ensure consistency.

Case studies in robotic innovation

These robots and their manufacturers exemplify the importance of mechanical positioning and its impact on dexterity and mobility.

FANUC and the LR Mate Series

FANUC is a pioneer in industrial automation. It developed the LR Mate Series of compact robots to assist in assembling complex products, such as electronics and medical devices. One metal stamping company, Pentaflex, utilized FANUC’s technology to improve assembly and efficiency with its legacy setup. Skillful implementation and positioning enabled the business to reduce labor units per shift while making the production floor more flexible.

The FANUC LR Mate 200iD, implemented in assembling complex products. | Source: FANUC

KUKA and the KR QUANTEC Series

German robotics manufacturer KUKA created the KR QUANTEC series for heavy-duty applications. It specializes in linear transfers, which help assemble large automotive or construction products.

Meiller Aufzugtüren is a door panel manufacturer that prides itself on high-volume, custom orders, regardless of batch size. It incorporated the KR QUANTEC robots, which helped keep production efficient with its welding. Two pedestal-mounted robots with unprecedented reach demonstrated the advantages of smart positioning.

In these spaces, the robots were able to handle spot welding, forming, stamping, and more. It made every bespoke order more precise by using consistent amounts of energy for each order.

Two KUKA KR QUANTEC models jointly perform welding services. | Source: KUKA

ABB and the IRB 6700

ABB created the IRB 6700 multi-axis robot to make tasks like fabrication easier to automate. It is the mastermind behind Japan’s most recent innovation – a 3D-printed railway station. The positioning of its vertical nozzle made it straightforward to manipulate mortar to design the components. The IRB 6700 also has seven axes of motion, enabling it to build a more complex structure, even on a less-than-ideal surface.

In only a week, it designed a practical yet aesthetically appealing structure that could be constructed in six hours. The flexibility and dexterity of machinery like this could save time and money when designing ubiquitous fixtures.

The IRB 6700 from ABB, complete with seven axes of motion. | Source: ABB

A future forged in collaboration

The future of every manufacturer lies in its scalability and buy-in to automated solutions. Digital transformation is setting competitors apart, and facets of robotics, like mechanical positioning, influence every aspect of automated assembly operations.

Robots will be more likely to deliver the benefits promised by innovators if mechanical positioning systems are optimized and interoperable with future technologies, such as artificial intelligence and machine learning. Then, the synergy between cobots and the workforce will be unmatched in terms of competitiveness and productivity.

About the author

Lou Farrell, a senior editor at Revolutionized, has written on the topics of robotics, computing, and technology for years. He has a great passion for the stories he covers and for writing in general.

This article is posted with permission.