March 2008 Edition
ROBOTICS
Where Reality Meets the Road
Simulating a solution provides robotic cells that work right out of the box
Before any robot is delivered, it is simulated from an inventory of robotic solutions available to Encore Automation
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 more than 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, ' 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.
EncorFlex systems can save from two to 10 months in delivery and 50 to 65 percent in cost
"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.
Cells are assembled in about a week and programmed in a day, with part run-off occurring the next day
"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." Dassault Systèmes
Visit www.rsleads.com/803mn-205 for more information
What do you think?
Will the information in this article increase efficiency or save time, money, or effort? Let us know by e-mail from our website at
www.ModernApplicationsNews.com or e-mail the editor at
pnofel@nelsonpub.com.