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Where Reality Meets the Road

Simulating a solution provides robotic cells that work right out of the box

(We are reprinting this from the Modern Applications News March 2008 issue due to its popularity.)

Progress and time are inextricably linked; each day brings advances, innovations, and ideas. A Eureka!” moment came to Encore Automation when engineers there had the idea that instead of designing individual customer-specific robotic workcells, they could predesign and pre-engineer cells for a variety of applications.

Manufacturing cost efficiency is critical,” Steve Becroft, president of the company based in Auburn Hills, MI, said. Custom-designed automation systems are too expensive for many companies. Our team thought of a way to bring automation to smaller industrial companies.

The company was formed in 2006 with key members of the Haden Automation Group. Collectively, they have installed and integrated over 700 robots for various material-handling applications. The company provides engineering, design, programming, robot simulations, and process feasibility studies.

Our collective experience in robotic work cell design prompted us to look at system commonalities and variances. By examining the parameters, we developed a standard robot cell design with flexible features to meet a variety of needs and applications.”

EncorFlex is a system based on a standard one-robot configuration, delivered on a two-piece platform that includes hosing, piping, and wiring, as well as part run-off. The modular system allows for assembly within an hour on the customer floor and the ability to run parts within 12 hours.

The Role of Simulation

EncorFlex systems begin with a virtual model. The company uses a physics-based, scalable Delmia Robotics simulation solution from Dassault Systèmes, Suresnes Cedex, France.

We simulate the initial cell, using a library of more than 500 robot models, in addition to application-specific devices such as paint guns or workpiece clamps,” Sean Parke, senior proposal engineer, said. We develop the best end-of-arm tooling for the job, then analyze the relationship between the part and the robot to determine reach requirements and potential collisions.

With simulation, we design an ergonomically correct cell. We analyze how close an operator can get to the part load device,” he said. Within a virtual world, we know, prior to build, that the system will perform properly. This eliminates trouble-shooting on the plant floor, saving tons of time and money.”

Once the system is simulated, it’s built at Encore’s facility, using prespecified standard components. All the hosing, wiring, piping, robotic programming, and run-off is done at Encore. Cells are assembled in about a week and programmed in a day, with part run-off occurring the next day.

The system is built on a two-piece platform featuring pre-existing holes for lift-truck fork insertion. One platform contains fencing, safety, and material handling devices. The other contains hosing, relay controls, robot controls, and dispensing tools. It takes only two bolts, in conjunction with a guide pin, to hook the two together.

The platform is key for robot-path programming,” Parke said. Because everything ships in place, no geometry adjustments are necessary. It arrives at the customer facility as it existed on our plant floor. The two platforms are connected, air and power are brought in, and full production begins.”

Encore discovered that Delmia is not only an efficient engineering tool; simulation also helps with the sales.

With 3D screenshots and videos, we illustrate for the client what will be delivered and verify cycle times, throughput, and other parameters,” Parke said. This eliminates guesswork and allows analysis of what-if scenarios, making it easier for the customer to justify the purchase.”

Time and Money Benefits

The obvious benefits of a pre-packaged system are time and money, according to Parke.

The EncorFlex lines are aimed at companies dealing with small- to medium-sized parts, handling volumes from 20 to 1,800 parts per hour,” Parke said.

He estimates EncorFlex systems can save from two to 10 months in delivery and 50 to 65 percent in cost.

There are additional benefits in using Delmia Robotic simulation, according to Parke. Most customer part data formats are supported via translators.

More importantly,” he said, once we’ve simulated the initial EncorFlex system, we don’t start from scratch each time. For each order, we simply reprogram the points based on the customer’s needs.”

Plans are to expand Encore’s use of simulation as new Delmia products are released.

Delmia is the standard,” Becroft said, Customers request these simulations more than any other format.”

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Dassault Systèmes

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