Industrial Robotics:

Current and Emerging Technologies and Applications

Sang Choi, ABB – US CRC Robotics

CASE 2012

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Applications

Contents

n Major drivers for industrial robots

n Current application areas

n Demands for non-traditional robots

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n Growing and emerging application areas

n Summary

The Top 10 Drivers for Industrial Robots

n Increase production output rates n Reduce operating costsn Improve process quality n Improve workplace health & safety n Increase product manufacturing flexibility

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n Reduce material waste and increase yieldn Reduce labour turnover and difficulty of recruiting workersn Save space in high value manufacturing areas n Reduce capital costs (inventory, work in progress)n Improve quality of work for employees

Based on research carried out by the International Federation of Robotics (IFR)

Applications - Overview

n Automotiven Foundry & Forgingn Metal fabricationn Machine Tools n Plastics & Rubber n Food & Beverage

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n Food & Beveragen Pharmaceuticalsn Transportationn Electrical & Electronics (3C)n Alternative Energy – Wind & Solar

Automotive industries

Application Areasn BIW (Body-in-White)n Paint shopn Trim and final assemblyn Sub assembly (ex. power train)

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Industry Drivers and Customer NeedsnCost competitivenessnHigher production outputsn Zero defects & consistent high qualitynManufacturing flexibility

Foundry & Forging industriesApplication Areasn Sand casting, gravity casting, die castingn Forging & lost foamnHandling, machine tending, casting cleaningnQuality control, surface treatment

Industry Drivers and Customer Needsn Precision and improved process controlnHealth & Safety

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nHealth & SafetynReduce of waste and increased yieldn Improve uptime, energy efficiency, productivity

Metal fabrication industriesApplication Areasn Agricultural, furniture, vehicles, 2-wheelers,

construction equipment, trains or shipsnCutting, welding, joining, pressingn Forming, inspection, measurment, paintingnMaterial handling, surface treatment, finishing

Industry Drivers and Customer NeedsnDemand for quality, capacity & efficiency

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nDemand for quality, capacity & efficiencyn Shortage of skilled manual workers nHealth and safety

Machine tool industries

Application Areasn Precision turning, milling, grinding and drillingnMachine tending and handlingnQuality control and Inspectionn Surface treatment and part finishing

Industry Drivers and Customer Needsn Shortage of skilled workers / rising labour costnGrowth in short run production

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nGrowth in short run productionnNeed for consistent high part qualityn Improvements in uptime and productivitynWorkplace health & safety

Plastics & Rubber industries

Application Areasn Automotive, electronics, medical and

household n Injection & blow moulding, thermo formingnCompositesnWater-jet, laser, ultra sonic and

mechanical cuttingnDispensing, gluing, foaming, painting

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nDispensing, gluing, foaming, paintingn Assembly, flame treatment

Industry Drivers and Customer Needsn Increased quality & reduced cycle timesn Short run productionn Added production value to secure marginsnReduction in direct & indirect labor costnWorkplace health & safety

Food & Beverage industriesApplication Areasn Food, beverage, pet-food, tobaccon Picking, Packing, Palletizingn Vegetable and meat processing

Industry Drivers and Customer Needsn Speed of deliveryn Prolonged shelf life of productsn Shorter product lifecycles, new

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n Shorter product lifecycles, new packaging designs and product variants

n Increased uptime, yield & zero breakages

n Safety and Hygiene

Pharmaceutical industries

Application Areasn Pharmaceutical drug discovery & productionnChemicals, medical devicesn Personal & home caren Picking, Packing, Palletizing

Industry Drivers and Customer Needsn Flexibility to handle different pack & product variants

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Flexibility to handle different pack & product variantsnQuality validation & traceabilityn Suitability for sterile production environmentsn Increased yield

Transportation industries

Application AreasnRailways – painting, welding, inspectionn Aerospace – painting, machiningn Two & Three Wheelers – welding, paintingnConstruction/mining vehicles – welding,

cleaning

Industry Drivers and Customer Needs

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Industry Drivers and Customer Needsn Increasing production capacity and

efficiencynReduction of production costnConstant high product quality outputn Improve workplace safety

Consumer electronics industries

Application AreasnComputers, mobile phones, digital cameras,

media players, games consoles, camerasn Laser welding, painting, grinding & polishingn Extraction, spraying, machine tendingnMaterials handling, assembly, picking, packing

Industry Drivers and Customer NeedsnQuality, precision and cosmetic finish

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nQuality, precision and cosmetic finish n Short cycle time and high volume productionn Short product life cycle production runsnRising cost of labor and demanding H&Sn Simple compact & flexible solutions

Alternative Energy – Solar & Wind industries

Application Areasn Turbine blade & tower – coating & weldingn Solar cell and module productionnMaterial handling (ingots, wafer/cells,

modules)nModule assembly, e.g. soldering, edge

trimming

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Industry Drivers and Customer Needsn Increasing production capacitynReduction of production costnConstant high product quality outputn Standardization of production plans

worldwide with high-end, flexible automation/robotics

More Industries …

n Electrical Machineryn Miningn Logisticsn Oil & Gasn Glassn Wood n Medical

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n Medicaln Papern Building materials & Constructionn Defense & Aerospacen Sanitary, Tableware & Ceramics

Demands for Non-Traditional Industrial Arms

Consumer electronics assembly

Pipe inspection

Tank inspection

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Logistics

Solar panel cleaning

Underwater exploration

Motor/Generator gap inspection

Mining / Excavating

Growing or Emerging Applicationsn Logistics

Ø Conveyorless material handling conceptØ De-centralized warehouse management system

n Robotics cooperating “Go-Green”

Ø Alternative energy product/systemØ Solar cells, fuel cells, rechargeable batteries for HEV/PHEV

n Mobile Applications n Service or Assisting Robot

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Ø New design is re-defining the traditional AGVØ Flexible and no need for altering the existing infrastructureØ Material handling, military and security applications

n Food IndustryØ Not just for palletizing, for actual processing Ø Arm/tool and food are in contactØ New styles complying with health, hygienic regulationØ New material, actuators, lubricants, packaging

Ø Defense (unmanned aerial or ground vehicle), AgriculturalØ Cleaning, Medical, Pharmaceutical applications

Summary

n Major drivers for industrial robots were discussed

n Current Application Areas were listed and detailed

n Many applications demand non-traditional Robots

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n Growing and emerging applications were introduced

(logistics, mobile, environmental, assisting, food-processing)