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ATM Vision Guided Robots

ATM’s Vision for the Future   ATM Automation is fast approaching its 40th year and during this time the company has come to be recognised as a leading supplier of Robotics and Automation within the United Kingdom. Over the years ATM has inevitably become involved in a broad range of applications which often require a unique combination of technologies to provide the optimum solution. With such diversity in applications, ATM’s philosophy of actively seeking out and embracing new technologies has proven to be a major contributing factor in the company’s ongoing success. As a further commitment to these principles, Vision Guided Robot Systems have become the latest addition to the ATM portfolio.   Flexible Alternatives to Dedicated Automation   ATM’s recent partnership with Nachi Robotic Systems, as a UK systems integrator for the full range of Nachi 6 and 7 axis robot systems, enables ATM to provide their customers with flexible and reliable alternatives to dedicated automation. As it becomes increasingly more difficult to justify capital expenditure, a flexible system which can be used for both current and future generation products becomes an ever more attractive option. When vision systems are added to the equation the prospects for even greater flexibility are significantly enhanced.   Nachi robots are available with the NVAX image processing system, which can be integrated to the AX Robot controller. This high-performance digital image processing technology, and image defect tolerant search tool, delivers outstanding object recognition. Together these features enable the system to be used in real world factory conditions and correctly identify features and parts. Nachi’s high speed search tool is tolerant of images which may differ from the “Ideal” image where the target object may be:-   - Darker or Lighter   - Rotated or Displaced   - Partially Obstructed or Dirty   - Smaller or Larger   - Placed on a Different Coloured Background   As a fully integrated system the NVAX system provides a high speed robot – vision interface which is easily programmed and operated via the robot teach pendant using the intuitive Windows™ environment. This also provides a single point of operation for both the robot and vision system.   Focus on Solutions   Nachi has developed various vision techniques using the NVAX system. Different combinations of - numbers of cameras, lighting and scanning techniques ensure that Nachi Vision Guided Robots can be applied to a multitude of guidance and inspection tasks.   Nachi has applied the NVAX Vision System to both 2D and 3D applications. Typical 2D applications, where a single camera is used, include capturing images of parts on a moving conveyor to identify their position and orientation. The information obtained by the vision system is then processed together with the travel speed of the conveyor, obtained from a separate encoder, to allow the robot to pick parts “On the Fly” and transfer them to the next part of the manufacturing process.   Three dimensional vision techniques (3D), such as using dual cameras to achieve Stereo Vision or using a single Camera and a Laser Scanner to generate an accurate 3D surface map of the component, allow the robot to perform even more complex tasks. These techniques enable the robot to process multiple part types and perform operations such as Random Bin Picking, an application where the Nachi Robot & NVAX Vision System together clearly excel. The capability to use a Vision Guided Robot for Random Bin Picking can provide a host of benefits. In these applications, the Vision Guided Robot eliminates the need for expenditure on dedicated part feeding systems or custom manufactured product specific trays and fixtures, which would generally be loaded by expensive manual labour. Eliminating the expensive dedicated tooling and manual labour costs together with the increased flexibility available from the system will often provide a return on investment which enables the project to proceed.   The latest development from Nachi, in the field of Vision Guidance, is Syncrovision (Patent Pending). This revolutionary technique allows the robot to move directly to the part by eliminating the need to “Pause” to acquire and process the image. Using dual cameras, and performing a “Pattern Search” the NVAX system identifies the best part for picking and calculates the precise position for the robot.   The prime advantage of Syncrovision is a much reduced cycle time, adding still further to the benefits already available from the NVAX system for Random Bin Picking applications.   With the addition of the Nachi range of Robots and Vision products to their “Core Technologies” ATM Automation can now apply the benefits of Vision Guided Robots to a wide range of applications and markets.   ATM Automation manufactures Cartesian robot systems and their ES robot range is renowned for speed and reliability. ATM also design and build bespoke automation cells incorporating Cartesian robots, 6 and 7 axis robots, plastics joining technology and assembly automation.

Seven-axis robot operates in confined spaces

ATM is now offering the innovative new Nachi MR20 seven-axis robot. In moulding shops it is common to see six-axis robots operating as part of an automated cell together with injection moulding machines. The uptake of six-axis robots has been a natural progression from more traditional three-axis Cartesian robots, given the additional dexterity and flexibility offered by the six-axis units. The only potential drawback when using a six-axis system is the extra floor space required to enable effective use of the large robot envelope.   The new MR20 robot features an unusual seven-axis design that enables the robot to emulate the motions of a human arm and perform more complicated tasks at high speed in restricted work areas. The robot can be situated close to the side of the injection moulding machine and use the dexterity of the seven-axis configuration to reach into the mould tool space. Another benefit of the new seven-axis system is the capability to avoid entering 'singularity' positions, which is a problem that can sometimes arise with six-axis systems and requires consideration during path programming.   Driven by Nachi's AX20 series controller, the MR20 features a horizontal reach of 1260mm, a 30kg payload and repeatability of +/-0.1mm. The MR20 is suitable for use alongside injection moulding machines, as well as in general machine tending, material handling and case packing applications. When coupled with Nachi's NV-AX vision system, the MR20 robot can also be used in bin picking and assembly applications.   ATM Automation also provides Cartesian and six-axis robot systems, plastics joining technologies, gripper and tooling systems, and complete systems, all of which are backed by the company's 40 years' experience in automation within the plastics industry.

Plastics joining lab opened

ATM has recently opened its in-house plastics joining laboratory. ATM has over 40 years experience of supplying the automation and plastics industries with a diverse range of technologies and solutions for applications such as demoulding, parts handling and assembly.   With component manufacturer’s now increasingly adding value to their product by performing more of the downstream assembly operations, plastic joining has become a key growth area for the company. This new resource, backed by the extensive experience of their plastic joining specialist, John Neugebauer, enables customer applications to be evaluated ahead of the proposal stage thus determining not only the best process for the application, but also enabling cycle times and process parameters to be defined in advance.   The laboratory has a number of different technologies available for evaluation including Hot Air/Cold Staking, Ultrasonic and Pulse Staking.   Each of the different technologies can be tried and tested on sample parts to determine the process best suited to the materials under evaluation. In some cases, there will be perhaps two or more technologies that can successfully join the parts. One of the technologies may be deemed more appropriate for a specific application depending upon the number of stake points or weld positions, cycle time and aesthetic appearance required.   Hot Air/Cold Staking is a traditional joining method which has been used for many years in a multitude of applications. Seen as a simple technology which can be used easily by un-skilled operators, this process is also relatively inexpensive especially where the components have multiple stake positions. The disadvantages of this process however include the fact that for a small number of stake points or tips the process is not particularly energy efficient. The process is not suited to hand held operation and also in some applications, the gap between the hot air nozzle and the stake point is critical if consistent quality is to be achieved. This renders the process less suitable for applications where the component tolerances may not be sufficiently tight. Additionally any concentration of heat energy applied to a confined area containing several stakes may stress relieve a moulded component causing unacceptable distortion.   Ultrasonic welding systems are used extensively for many applications, but as for other joining processes, this too has limitations. When applied to materials with a high glass or mineral fill content (40% to 50%) the ultrasonic process can cause particle fragmentation, which is unacceptable in certain safety critical applications found in the production of Aerospace or Military components and automotive seat restraint and air bag applications. The use of ultrasonic welding on electro-mechanical components and PCB’s can also pose a problem due to the high frequency vibrations generated, as can the use of the technology in close proximity of metal components. Consideration must also be given to the noise generated by the process, and appropriate steps must be taken to prevent prolonged operator exposure to the high frequency sound. Ultrasonic welding does however have a number of advantages. It is possible to have a hand held unit which enables the use of the technology on low volume production or where a dedicated multi-tip machine cannot be justified. The process is also quick and can generally be used on a wide range of materials. Where multi tip applications are required, a number of sonotrodes can be operated from a single generator unit by switching from one tip to another in a pre-defined sequence, thus helping to reduce the overall cost of the machine.   A less well known process, pioneered by ATM, is “PulseStaking” technology. Available as a portable hand held device or integrated into multi head desk top or floor standing machines, PulseStaking works by accurately controlling the amount of time a current passes through a specially designed tip which is rapidly heated to the melt temperature of the material being processed. The current is “pulsed” on and off to ensure that the material does not overheat and begin to degrade. At the end of the “pulsed” heating cycles, compressed air is passed through a central tube which rapidly cools the tip and allowing the plastic to solidify rapidly. The small heat affected zone around the PulseStaking tip, plus the fact that the process does not generate any vibrations, makes PulseStaking ideal for applications on electronic components and PCB’s. The process is also unaffected by the close proximity of metal components and the controlled nature of the heating cycle also makes it more suitable for materials which have a high filler content.   Hybrid machine   Selecting the most appropriate process for an individual application can mean that on occasions two different technologies will be used together within a “Hybrid” machine. One such example was a rotary table welding machine for the production of powder print cartridges. This machine employed ultrasonic technology to weld a plastic cap onto one end of the cartridge housing whilst a multiple tip Pulse-Stake heat staked an ID tag in the form of a small PCB at the other end of the assembly. With a very localised heat affected zone and with no vibrations generated from the process, Pulse-Staking was deemed to be the most appropriate technology for this part of the assembly process. This “Hybrid” machine operates very successfully and is an excellent example of the unbiased approach adopted by ATM for every individual application. ATM also has experience with other plastics joining technologies such as Hot Plate Welding, Vibration Welding and Laser Welding.

ATM Automation offers multiple plastic joining technologies

ATM Automation Cuts Through Polypipe's Flash Problem

ATM SCOOPS 6 AXIS ROBOT DEAL

ATM Automation Limited, the leading manufacturer and supplier of robots and automation to the plastics industry, have recently installed 3 off ATM Nachi 6 axis robots into an application that would have been historically considered the domain of 3 axis robots.   The application involved installing these robots next to 3 separate injection moulding machines in an area with quite restrictive space constraints.   ATM Automation was chosen from several suppliers considered because of the quality of the robots together with ATM’s ability to supply and integrate further automation at a later date. The service and support facilities that ATM can offer were also major considerations.   Mr Geoff Lomax – Engineering Manager of Sangenic International who make the Tommee Tippee Nappy Wrapper for worldwide distribution says   “Our moulding machines and robots were due for replacement. Rather than simply replace the old 3-axis robots we chose to upgrade our capabilities with automation in mind. Currently, the 6-axis robots are tasked with de-moulding highly polished components but in the future they will form the centrepiece of our automated assembly cells.   By investing in the superior capabilities of these robots now the cost of future automation is significantly reduced. The versatility of these robots means they can be simply re-tasked as products develop or change. If required, they could be easily moved off-line to carry out other assembly or packing operations.”   Jason Shuttlewood – Sales Manager for ATM explained that ATM are in a unique position, as a manufacturer of 3 axis robots and a leading integrator of 6 axis robots, to offer their customers an unbiased view on the best option for them and he says   “We have found that while the number of new moulding machines and hence requirement for new robots for standard pick and place applications remains fairly static this year (although still important), there has been significant growth in other areas of business.   These are mainly split into 2 areas.   The first is a significant increase in robotic automated cells that integrate additional processes into the system to reduce the labour cost and increase efficiency. Typical applications include insert loading, packing, in mould decoration, assembly and degating.   The second growth area is cell enhancement whereby we automate these processes around an existing robot and moulding machine. The rational again being to reduce costs and improve efficiency.”   The Nachi robot is well established among major Japanese automotive OEM’s in the UK and has become increasingly popular in the plastics sector.

ATM ROBOT INSTALLED AT FLEXIBLE LAMPS

An ATM six axis robot has been employed at Harlow-based Flexible Lamps to load L-shaped pins into similarly shaped recesses in injection moulded housings for commercial vehicle side marker lamps.   The robot is part of a production cell incorporating a Negri Bossi NB 160 tonne machine, which moulds the ABS housings in a twin impression tool on 32 second cycle. The mouldings are first extracted from the tool by the robot, located at the rear of the machine, and precisely positioned on a jig. Moving simultaneously in three axes, the robot then picks up a pair of pins from a linear track leading from a bowl feeder and carries them over to the housings.   Wrist rotation through 45o is then performed and the pins are lowered into the recesses in this orientation. When the pins almost reach the bottom of the recesses, the wrist is rotated to its original position and the components are accurately deposited into place. They are then released and the robot withdraws.   ATM and Flexible Lamps co-operated closely in developing the cell, which was set up and tried out at ATM’s Leicester factory before delivery to Harlow. This ensured that only fine tuning was required when the equipment was delivered and commissioned on site and minimised make ready time.