Robotic Tape Application
by Terry Sharp
Robotic Industries Association Posted 08/16/2006
Product or Part Automated: Side Body Molding
Robot Vendor: Fanuc
Robot Model or Type: M16i
Robot Integrator: Two Stage Innovation
Submitted by: Terry Sharp PEng
Company: Two Stage Innovation Inc.
Customer wanted a flexible tape application system for a variety of parts. Idustry search along with other company contacts lead them to consider our Robotic Tape Application Technology. This technology features a flexible cell capable of applying various widths of tape to infinite configurations of parts. The patented technology won out due to the speed, flexibilty and repeatbility of the systems.
Description of Process or Solution
Our solution involved 5 systems. Each robot system consisted of a Fanuc M16i robot with Applied Robotics tool changers equipped with a number of our Tape Application and Adhesion Promoter tools. The operator loads parts on a 180 degree table and unloads in the same position. Each set of fixtures is 'quick change' and automatically recognised to ensure selection of robot programs and appropriate tools. Parts rotate to the robote for adhesion and tape application. Built in error proofing ensures application of promoters, tape and monitoring tape level and fluid levels. Built in process monitoring software monitors the system throughput and downtime associated with the manual load process. Handshaking with HVAC equipment ensures proper ventilation before the process can begin.
Success was measured primarily in payback as a result of labour reduction and long term tooling cost reduction. Due to the robotic application, tooling changes and programming are the only additional cost for future programs. Less labour is required since the robots can apply the adhesion promoters and tape faster and more consistently than manual or 'in-line' systems. Floor space reduction and better material flow were additional factors. Reduced exposure to adhesion promoters and repetitive strain injury reduction were benefits from moving to this technology.
Provide justification benefits by which this case study might be categorized. Indicate as many as applicable, but please be selective and indicate the most important drivers rather than choosing all if possible.
Labor Savings: Yes
Injury/Risk Reduction: Yes
ANSI/RIA R15.06-1992: Yes
Risk Assessment: Yes
Industry: Automotive Supplier
Total Robots Installed: 5
Key Peripherals Installed: Camco Indexers, AB PLC & Panelview
Date Installed: From Sept 05 to April 06
Number of production shifts associated with this robotic application: Three