Robotics Projects Archives - Page 2 of 3

Custom Designed Inspection Robotic Cell for the Food Industry

greencrest on March 27, 2022

Serving a customer in the food inspection industry, MJ Engineering designed this inspection robotic cell, working from a set of specifications provided by the client. These cells are designed with the purpose of eliminating the need for product destructive testing. Chief among the requirements was meeting cell testing protocols, as well as compatibility with existing custom specification inspection devices for the inspection system. Using SolidWorks, we created 3D models of the cell concept, ensuring proper interface and operation upon manufacture and installation.

A key feature of the inspection cell is the FANUC LR Mate 200iC 5H Series robot with integrated iRVision system, which provides highly repeatable and accurate placement of inspection items on the processing conveyor. MJ Engineering also provided electronic documentation, and operation training for equipment users, as well as ongoing long term product testing support.

Project Description

This Custom Designed Inspection Robotic Cell is used to inspect food products.

Capabilities Applied/Processes

Cell Design

Conception of Cell that Meets a Variety of testing Protocols
Create SolidWorks 3D Models of Cell Concept

Inspection System Design

Must Interface with Custom Spec Inspection Devices
Complete Detailed Cell Design

Installation
Start-Up
Documentation

Provided ElectronicallyTraining
- Operation Training Provided

Long Term Product Testing Support

Features/Benefits

Features

Utilizes FANUC LR Mate 200iC 5H Series Integrated iRVision System
Automated Product Tracking
Orients Packages on Incoming Conveyor Line
Up to 60 Individual Units Per Minute
Positive Rejection of Identified Defect Packages

Benefits

Vision System Provides Accurate & Repeatable Placement on the Processing Conveyor
Greatly Reduces need for Destructive Testing

More Info

Overall Cell Dimensions
Length: 96″
Width: 48″
Height: 72″

Tightest Tolerances
Pick and Place within 1mm

Material Inspected
Nutritional Supplements

Industry for Use
Food

Delivery Location
Ohio

Standards Met
Customer supplied specifications

Product Name
Custom Designed Robotic Cell for Food Inspection

Custom Designed Robotic Bag Palletizing

greencrest on March 27, 2022

A large farm feed supplier was in need of automation on a high volume bag filling line. The production on this line is typically 8000 bags per shift. The pre-automation method of palletizing the bags included many material handling personnel.

This bag filling line is capable of a wide range of fill weights and bag sizes so the automated system needed to be flexible and easy to change from product to product.

The Fanuc robot and cell that MJ designed and installed was able to meet the flexibility requirements and maintain a small space requirement. By utilizing the (DCS) option and a custom cell design MJ was able to offer a cell with a footprint much smaller than the competition. Dual Check Safety (DCS) Position and Speed Check software option, from Fanuc, provides safety rated speed and position monitoring without additional hardware or external switches or relays.

Project Description

This robotic cell automatically palletizes bags on one of two pallet stacking locations. This along with Fanuc DCS© and the installed safety system allow for continuous palletizing operation.

Capabilities Applied/Processes

Cell Design

Conception of cell that meets capabilities of varying bag sizes
Create SolidWorks© 3D models of cell concept

Installation
Start-Up
Operator and Maintenance Training

Features/Benefits

Features
Fanuc DCS and Pallet Tool are utilized in this cell. DCS provides the internal robot safety check on speed and position that are used with the external safety controls to provide a safe method for the operator to work with the robot cell. One filled pallet on station 1 can be exchanged for an empty while the robot is filling station 2 and vise versa.

Benefits
Hi Speed palletizing of bagged feed and corn, up to 18bags per minute.
Multiple bag sizes from 25lb to 50lb and multiple pallet stacking styles can be selected
Bag conditioning and conveying to robot cell were provided.
Small footprint.
Based on the Fanuc M410/140 which provides very high reliability.

More Info

Overall Cell Dimensions
160″ x 192″

Pattern Size Capabilities
25lb bags to 50lb bags

Tightest Tolerances
NA

Material Used
None

In Process Testing Performed
The system was tested on a pallet of each bag size prior to being shipped to the customer for install.

Industry for Use
Manufacturing/Agriculture

Delivery Location
Ohio

Standards Met
Customer supplied part pallet stacking styles

Product Name
Robotic Bag Palletizer

Custom Designed Collaborative Robotic Assembly Cell Application

greencrest on March 27, 2022

A plastic injection molding manufacturer was in need of a collaborative automation system to aid the task of tendng an ultrasonic welder. The weld process has a fast cycle time that required a full-time person to tend the process and inspect each part after the weld was complete. The Universal robot was selected due to ease of programming and its collaborative rating.

Upon completion of the risk evaluation it was determined that the guarding could be reduced substantially compared to a traditional robot. This allows the operators to interact with the robot cell while it is actively tending the welder.

The automated inspection is completed using a SICK smart camera to detect presence of cracks in the material caused by the weld process. Including the automated inspection task makes the automation of this tending application possible.

Project Description

This Custom Designed Robotic Cell is used for tending an ultrasonic welder.

Capabilities Applied/Processes

Cell Design

Conception of Cell that Meets Unique Production Requirements
Safety audit based on current RIA standards
Create SolidWorks 3D Models of Cell Concept

Tooling Design

End of Arm Tooling (EOAT) Design
Automated vision inspection system
Inspect each part after welding for stress cracks
Isolate any potential defects

System Assembly

Assemble program and pre-ship testing of the cell

Features/Benefits

Features
Utilizes Universal UR5 – Collaborative Robot

Use of a collaborative cell allows minimizing of physical guarding and associated safety control devices.
Automated tending of an ultrasonic welder by picking assemblies from a tray and placing them into the welder fixture. The fixture clamps the part and executes the weld cycle. When the weld cycle is complete the robot picks the assembly and presents it to the vision inspection station. Pass and Fail parts are isolated from each other.

Benefits
Provides production rates and consistency that is not capable with manual procedures.
Improved safety by removing the operator from the high noise area created by the ultrasonic welder.

More Info

Overall Cell Dimensions
72″ long x 60″ wide

Custom Designed Robotic Cell Tank Palletizing

greencrest on March 27, 2022

A propane tank manufacturing client approached MJ Engineering to design and install a custom robot cell for the purpose of automatically palletizing 20 and 30 lb tanks. The task had been done in the past by operators manually stacking the tanks on a motorized section of lift conveyor. The desire was to have a fully automatic cell that would build the pallet based on a customer specification and then apply the wrap to create a pallet that was ready to ship.

The cell interfaces to a pallet dispensing system and pallet wrapping station to complete the fully automated tank palletizing process.

The robot EOAT (End Of Arm Tool) is designed to handle the tanks, tier sheets and pallets. The pallet building process starts with the robot picking and placing a pallet in the stacking position. The robot then picks tanks and tier sheets as needed to build subsequent layers.

Additional support was provided to the client for controls and programming of the conveyor and pallet dispenser.

Project Description

This custom designed robotic cell is used for picking and palletizing propane tanks, both 20 and 30 pound sizes.

Capabilities Applied/Processes

Cell Design

Conception of cell that meets unique production requirementsand existing floor plan configuration.

Tooling Design

End Of Arm Tooling (EOAT) Design/li>

Installation
Start-Up
Operator and Maintenance Training

Features/Benefits

Features

Individual tanks are delivered into the cell via the common chain conveyor.
Automatic tool changer to allow handling of boxed and un-boxed tanks./li>

Benefits

Provides speed and consistency that is not capable w/ manual procedures
Reduces the need for operators to manually handle tanks during the process.
Capable of picking 20 lb and 30 lb tanks, both boxed and un-boxed.
Automated pick and place of tanks, pallets and tier sheets using a single multi-purpose EOAT design./li>

More Info

Overall Cell Dimensions
180″ x 130″

Size Capabilities
20 lb and 30 lb, boxed and un-boxed propane tanks

Tightest Tolerances
+/- 0.2mm

Material Used
None

In Process Testing Performed
The gripper system utilized on the EOAT was tested prior to installation of the cell in the plant.
Pre-Ship runoff of a full pallet of tanks was provided at the MJ Shop prior to shipping to the customer site.

Industry for Use
Consumer products

Delivery Location
Westerville, Ohio

Standards Met
Customer supplied print, 2D Auto CAD Drawing

Product Name
Custom Designed Robotic Cell Tank Palletizing

Robotic Weld Cell

greencrest on March 27, 2022

Additional Unit Information
Input Voltage	460vac, 30
Compressed Air	90 psi
Robot Capacity	10Kg/20Kg
Robot Reach	1098mm/2009mm
Unit Weight	~1700#

Project Description

The MJ Engineering Robotic Adhesive/Weld Cell is a portable arc welding cell that can be used for welding or applying a wide range of adhesive products a wide range of assemblies. The cell is completely customizable to meet the needs of various industries including automotive and applicance.

Features/Benefits

Features

Robot FANUC ArcMATE 100iC robot
- R30iB Controller
- Installed DCS package – Speed and position check for safety
Rotary table with 2 fixture bases
Light curtain at operator access
Portable Cell
Short lead time

Benefits

Safety

Meets RIA Standards
SICK Light curtains
Door Interlocks

Reliability and Efficiency

Allows speed and consistency that is not capable with manual procedures
Increased production rates
Eliminates setup time for operator
Control System allows for storage and easy retrieval of multiple programs
Easy access for maintenance

Portable

Can be moved by forklift

Options

Robot Model
Integrated touch screen operator interface panel
Power source, compatible with most common power supplies
Torch
Wire feeder
Aux axis indexer
Fixture design/fabrication
On-site installation
On-site training
On-site programming
Ventilation mounts
Intergrated Vision Inspection/Guidance