Robotic arms aid labelling and assembly

Auckland-based plastic injection moulding company TCI New Zealand was looking for an automated, cost-effective way to produce its customers’ products and decided to investigate using 6-axis industrial robots. Now, TCI is using Universal Robots’ UR3 and UR5 industrial robotic arms to perform labelling and assembly tasks for the EasiYo Yoghurt Maker line, as well as its storage bins.

With a Universal Robot assisting, several key processes in the manufacture of these products have been automated, relieving employees of repetitive assembly processes and ensuring smooth production flow.

The UR3 was the first machine implemented by TCI, with the costs of the robot recouped six months after it was first purchased. Satisfied with this return on investment, TCI then decided to purchase the UR5, with the payback period expected to be under 12 months.  

“Previously we were paying two employees to work in 12-hour shifts to ensure around-the-clock production of our EasiYo Yoghurt Maker. If one employee didn’t turn up for work, it meant the entire production line would be halted. This wasn’t really financially sustainable for us, so we were looking for an automated solution that would guarantee quality assurance and help us to reduce costs,” said Quintin Fowler, managing director at TCI.

During its search for an automation solution, TCI came across Universal Robots’ technology at a trade show and made contact via Design Energy, Universal Robots’ New Zealand distributor.

“We developed the layout for the production cell and designed and built an appropriate gripper unit for each of the applications,” said Mike Shatford, managing director at Design Energy. “TCI then manufactured the machine frames and mounted the various operating units in the relativities we had laid out. Once the machines were completed, our technician spent time at TCI writing the robot programs and getting each cell operating to the customers’ requirements.”

“Design Energy were fantastic. We were initially considering an off-the-shelf robot from overseas, but I’m glad we were able to find a customisable solution,” said Fowler.

All UR robots can be completely reprogrammed and deployed for other tasks in a matter of minutes. A graphical user interface with a teach function enables an operator to simply grab the robot arm and show it how a movement should be performed. The user-friendly interface then allows staff to drag and drop the routines to do their programming.

In contrast to traditional industrial robots in the market, Universal Robots’ small and lightweight robotic arms are able to work safely alongside staff (subject to prior risk assessment). The robots’ state-of-the-art force limit safety feature automatically stops the robot from operating when its movement is obstructed. The robot will not exert a force greater than the limit specified in the adjustable safety settings.

“One thing I loved about Universal Robots was that we didn’t have to worry about guarding, whereas [for] a lot of the other robots in the market guarding was an issue because you’d have to use safety barriers for all the machines, which just complicates the situation,” said Fowler.

Originally published here.