Automation is becoming more and more prevalent in the assembly world, as the labor shortage persists and manufacturers look to make their lines more productive, efficient and less prone to errors.
This shift from manual production methods has also been accelerating thanks to the fact that automation tools are becoming cheaper and more flexible.
Furthermore, following the massive supply-chain issues that were caused by the COVID-19 global pandemic, more European and USA-based manufacturers have started repatriating some of their production lines. These manufacturers understand that relocating some of their operations on-shore can’t happen without adopting industrial robots who alleviate labor shortage issues; at the same time, reviving their domestic factories means that more jobs become available for skilled programmers that can deploy, calibrate and maintain these high-tech devices.
Generally speaking, automation in the factory provides several advantages to manufacturers, including:
- reduced reliance on assembly-line workers, of whom there is far more demand than supply
- increased uptime in the production line, as robots can work around the clock, scheduled maintenance aside
- superior quality and fewer defects, as human errors are virtually eliminated
- reduced costs, thanks to more precise and efficient production processes
Therefore, in order to remain competitive and profitable, manufacturers are rapidly increasing their investments to modernize their assembly lines, integrating Industry 4.0 standards, AI, robotics and sensors into their production processes.
We have already introduced the concepts of Industry 4.0 and full-traceability and how they can improve the fastening process, so today we will look at the latest trends in robotics.
TRENDS IN ROBOTICS
Some key major trends we are seeing in the robotics world are:
- Vision-guided robotics
Robots now use cameras to locate fasteners and ensure that they are correctly installed. Advanced image processing algorithms improve the accuracy and speed of the fastening process and augment it with post-fastening quality control checks. - A move towards energy efficiency
As sustainability continues to be a major focus of the industrialized world, robot manufactures have also been making substantial improvements in reducing the energy consumption of their products. These improvements include regenerative braking (similar to what electric vehicles do) and simplified programmer interfaces that make it more intuitive to optimize the layout and operating speed for the application at hand. - Improved human-robot collaboration
Innovative new interfaces and communication protocols are allowing for increased levels of interaction and collaboration between operators and robots. For instance, some cobots can now respond to voice commands or hand gestures, making it easier for humans to control their movements and perform more complex tasks. Furthermore, AI integration allows robots to learn and apply new tasks that are taught to them, without necessitating repeated instructions, and improving performance over time. - Increased payload capacity
Newer collaborative robot models have been developed with higher payload capacities, allowing them to handle heavier objects and perform more demanding tasks. - Enhanced safety features
Manufacturers are increasingly prioritizing safety features in cobots, with developments in areas like force sensing and collision avoidance that allow cobots to work safely alongside humans. - One-up assembly
The aerospace industry is also implementing automation at a rapid pace, particularly when it comes to one-up assembly, where aircraft components are assembled in a single continuous operation without the need for fastening and unfastening of parts for deburring, cleaning, and sealing. This is achieved by maintaining part clamp-up and carefully controlling drill bit geometry and fastening precision, tasks that are best suited for automation than for manual work. When implemented properly, one-up assembly reduces assembly time, minimizes floor space needs, improves product quality, and increases efficiency in the manufacturing process, quickly returning the investment that companies put in to automate the production line.
KOLVER AND ROBOTICS
Kolver’s CA Series is designed specifically for automated and fixtured applications. The special aluminum-body versions of our electric screwdrivers make integration with automatic machines and screwfeeding systems quick and easy, while the screwdriver controllers connect directly to the robots to signal the status of the tightening operation. Torque and angle data is collected and analyzed automatically, guaranteeing maximum precision and accuracy, and facilitating quality control.
Check out Kolver’s YouTube channel to view video demonstrations of our PLUTO and K-DUCER screwdrivers paired with various collaborative robots.
For instance, here’s a setup by Allied Automation displaying a UR UR16e delivering a 16 kg (35 lb) payload using a K-DUCER fastening system and illustrating how this can be done effectively and error-free, all within a very small working area.
Overall, the latest trends in collaborative robots are focused on making them more green, versatile, intelligent, and safe. By adopting these technologies, businesses can increase their productivity, efficiency, and quality while reducing the risk of accidents and injuries.
On a more macro level, the trend towards automation and the use of robots in assembly lines is expected to continue, as the benefits of automation become more apparent, and the cost of automation technology continues to decrease.