At a glance, machine tending is a relatively simple process. First, operators must load raw materials. Once machined, they need to unload the finished part– rinse and repeat. Because these materials vary in size and weight, and the processes are repetitive, these tasks can quickly become challenging for any operator.
The solution? Machine tending robots. With the latest technological advancements in the manufacturing industry, machine operators no longer need to injure themselves on the job just to load and unload materials. These repetitive processes are now frequently handled by robots so operators can focus their skills on more demanding tasks. Here’s everything you need to know.
Quick Links
Before delving into the details of machine tending robots, let’s first discuss machine tending. Machine tending refers to the process of loading and unloading materials or parts into and out of industrial machines, such as CNC machines. While this is a vital procedure for many manufacturing processes, this can quickly become repetitive and taxing for operators.
Fortunately, machine tending can be completed with the help of automation, which is where machine tending robots come into play.
A machine tending robot is a type of industrial robot designed to automate the process of loading and unloading materials or parts into and out of machines. This process, without automation, is often, as noted, tedious and dangerous, or it requires high precision. Thanks to automation, workers are free to focus on more complex activities which the robots tackle repetitive machine tending.
This automated cycle not only enhances productivity by significantly reducing machine downtime but also ensures consistent quality by eliminating the variability associated with manual handling.
Of course, these innovative automation tools weren’t always in use. Initial attempts at automation involved simple mechanical devices that could perform repetitive tasks, but these machines were limited in their functionality and required significant human supervision and intervention.
In the late 1960s and early 1970s, computer numerical control (CNC) gained some momentum in the manufacturing industry. CNC technology allowed for more precise and flexible control of machining processes, paving the way for the integration of robots into manufacturing environments. Early machine tending robots were often bulky and expensive, but they started to demonstrate the potential for improving efficiency and consistency in production lines.
By the early 2000s, the development of more sophisticated sensors, better control systems, and enhanced software capabilities allowed machine tending robots to handle more complex tasks with greater accuracy. And in recent years, the evolution of machine tending robots has accelerated with the incorporation of artificial intelligence (AI) and machine learning technologies. These advancements have enabled robots to become more autonomous, adaptive, and capable of performing tasks that require a higher level of decision-making and problem-solving.
Innovations in vision systems and sensor technology have further enhanced the ability of robots to interact with their environment and perform quality inspections in real-time. Additionally, the rise of the Industrial Internet of Things (IIoT) has facilitated better integration and communication between robots and other machinery, leading to smarter and more efficient production systems.
Overall, machine tending robots play a crucial role in modern manufacturing by improving efficiency, enhancing safety, and ensuring consistent product quality. As technology continues to improve and automation becomes more prevalent, it’s clear that machine tending robots have become indispensable in modern manufacturing.
Machine tending robots can be categorized into two main types: industrial robots and collaborative robots (cobots). Each type has unique characteristics and applications that cater to different manufacturing needs.
Let’s start by taking a look at the larger robots on the market. Industrial robots are the traditional workhorses of manufacturing automation. These robots are typically large, powerful, and capable of handling heavy-duty tasks with high precision and speed. So, with these features industrial robots are commonly used for repetitive, high-volume operations, such as those found in automotive assembly lines and metalworking facilities.
Collaborative robots, or cobots, represent a significant advancement in robotic technology. These robots are smaller than industrial robots and are designed to assist operators with manual tasks. Cobots are generally small and flexible, making them suitable for a wide range of applications, including small-batch production, assembly, and quality inspection. Their ease of programming and reprogramming, often through intuitive interfaces or manual guidance, makes them accessible to businesses of all sizes, enabling rapid deployment and adaptation to changing production needs.
Machine tending robots are comprised of several key components working together to perform their tasks with precision and efficiency. These components include robotic arms and grippers, control systems, and sensors and vision systems.
The robotic arm is the central component of a machine tending robot, designed to mimic the movements and dexterity of a human arm, also known as end-of-arm tooling (EOAT). These arms come in various configurations, such as six-axis or seven-axis designs, which provide a wide range of motion and flexibility.
At the end of the arm is an end effector or gripper, which can be tailored to handle specific materials or parts. Grippers can vary from simple mechanical jaws to sophisticated vacuum or magnetic grippers, depending on the nature of the materials being handled.
In order for machine tending robots to be automated, they need sophisticated control systems which dictate the movements of the robots. These systems are typically made up of programmable logic controllers (PLCs) and human-machine interfaces (HMIs).
PLCs are industrial computers that execute pre-programmed sequences of operations based on inputs from sensors and commands from operators. In order to adjust programing, HMIs provide a user-friendly interface for operators to interact with the robot, program tasks, and monitor performance.
Sensors and vision systems play a crucial role in enabling machine tending robots to interact with their environment. Sensors, such as proximity sensors, force sensors, and tactile sensors, provide essential data about the robot's surroundings, the position of objects, and the force applied during handling. Vision systems, which include cameras and advanced image processing software, allow the robot to recognize and locate objects with high accuracy.
Sensors and vision systems are closely linked to the dexterity of machines tending robots and are essential for high functioning, automated processes. The robotic arm and gripper provide the physical capability to manipulate materials, the control systems ensure precise execution of tasks, and the sensors and vision systems enable perception and adaptation to the environment.
Together, these systems enable tasks such as identifying parts, inspecting quality, and ensuring correct placement within machines, ultimately enhancing the robot's ability to perform complex tasks autonomously and adapt to variations in the production process.
We know and love robots for their ability to make our lives easier through automation, but how are these robots actually put to use? Machine tending robots are quite flexible in their abilities so it makes sense that these tools have become essential for practically every industry that requires machining.
Machine tending robots are widely utilized across various industries due to their ability to enhance productivity, precision, and safety. Here’s a look at how they’re frequently used in several industries:
Machine tending robots are highly versatile and can perform a variety of tasks that enhance the efficiency and accuracy of manufacturing processes.
If machine tending robots are used in a plethora of applications, then there must be a reason why. While this list is quite extensive, we’ll touch on a few key benefits that stand out.
Machine tending robots significantly increase efficiency and productivity in manufacturing businesses through their ability to perform repetitive tasks with high precision and speed. One of the key ways they achieve this is by reducing cycle times, which is the total time required to complete a manufacturing process from start to finish.
By automating tasks such as loading and unloading parts into machines, transferring materials, and handling finished products, robots minimize the downtime between operations. Unlike human workers, robots can operate continuously without breaks, fatigue, or variations in performance, leading to faster and more consistent production cycles. And, with accuracy and precision, operators won’t need to waste defective parts or restart their production if their machine tending robots are able to repeatedly generate the same results.
In many manufacturing settings, certain tasks expose workers to hazardous conditions, such as high temperatures, toxic chemicals, heavy machinery, and sharp objects. These elements can put the safety of workers at risk, especially if they become fatigued from physically demanding and repetitive tasks. Fortunately, machine tending robots can be programmed to operate in these environments.
By using robots, manufacturers can significantly reduce the exposure of workers to harmful conditions. Not only can these robots eliminate human intervention in strenuous tasks, but they can also allow for the redesign of workspaces to be more ergonomic and safer for human workers. With robots handling the most hazardous tasks, production lines can be organized in a way that reduces clutter and enhances workflow, creating a safer environment for employees. This leads to fewer workplace accidents and injuries, contributing to a more productive workforce.
The manufacturing industry, like many others, is facing labor challenges. It can be difficult, and costly, to find, hire, and train operators to work with advanced machinery. Fortunately, machine tending robots can assist with lower labor expenses by reducing the reliance on costly manual labor. This doesn’t mean that businesses should be replacing their staff with robots. Instead, machine tending robots can help operators with repetitive tasks so they can focus their efforts on tasks that require their skills, enhancing overall productivity.
Additionally, machine tending robots contribute to cost savings by minimizing machine downtime. In manufacturing, any period when machinery is not operating optimally represents a loss in potential output and revenue. Manual tending can introduce variability and delays, as human workers are subject to fatigue, errors, and inconsistencies.
In contrast, robots can perform tasks with high precision and consistency, ensuring that machines are loaded and unloaded efficiently and accurately. This round the clock operation maximizes the utilization of production equipment, leading to higher throughput and reduced idle times.
Moreover, machine tending robots can be programmed to perform maintenance checks and alert operators to potential issues before they result in downtime. Predictive maintenance enabled by sensors and data analysis can further reduce unexpected breakdowns and extend the lifespan of machinery. By maintaining a steady and predictable workflow, robots help keep production lines running smoothly, thereby reducing the costly interruptions associated with manual interventions.
While machine tending robots can resolve many challenges faced by job shops and manufacturing businesses, there are still some considerations to be taken into account. From aligning new technologies with existing systems to training operators on new systems, it may require some careful evaluation before introducing robots into your production.
One of the primary challenges is ensuring new machine tending robots are compatible with existing machinery and software systems in a manufacturing facility. Many factories have a diverse range of equipment, often from different manufacturers which vary in age and technology. Integrating a modern robot with older machines can be difficult due to differences in communication protocols, control systems, and mechanical interfaces.
For instance, older CNC machines or production lines may not have the necessary digital interfaces to connect with contemporary robotic systems, requiring additional hardware or software modifications to facilitate integration. For maximized efficiency, machine tending robots should be able to seamlessly integrate with existing machinery and software.
Implementing machine tending robots in manufacturing businesses often involves significant initial investments, which can be a considerable challenge for many companies. The upfront costs of purchasing the robots and integrating them into existing production systems can be substantial, especially for smaller job shops.
Additionally, while the long-term benefits of automation—such as increased efficiency, reduced labor costs, and improved product quality—are well-documented, the payback period for these investments can vary significantly. For some businesses, it might take several years to recoup the initial investment. So, accurately calculating ROI is essential for business planning.
Effective operation requires skilled staff, and which in turn demands time devoted to technical training. Some manufacturers might have employees with limited experience with robotics and automation. As a result, these teams require comprehensive training to bridge skills gaps, including how to program and troubleshoot robots, understanding the integration of robotic systems with existing machinery, and developing proficiency in using control systems and human-machine interfaces.
Beyond technical training, fostering acceptance and enthusiasm for robotic automation among employees can be challenging. Further, the transition to a more automated manufacturing environment can be disruptive if not managed carefully. Job shops and manufacturing companies should gradually integrate robots into the production process while ensuring that employees are adequately prepared and supported. This may involve running pilot projects, gradually scaling up automation efforts, and continuously monitoring and addressing any issues that arise.
While these challenges are worth noting, they shouldn’t be roadblocks in the adoption of new robotic tools. Proper planning and evaluation of machine tending robots will be vital before purchasing and implementing robotic automation equipment.
Earlier we discussed some use cases for machine tending robots, including material handling and quality inspection. For Gilco Manufacturing Inc., machine tending robots were an essential addition to their contract manufacturing business.
When it comes to contract manufacturing, these businesses need to be agile in order to serve a wide variety of customer demands. Whether a customer is looking for products to be painted or machined, Gilco’s machine tending robots contribute to enhanced efficiency and consistency across their processes.
Once these robots were integrated into their shop, the Gilco team noticed that their AWR machine tending robot gave them the ability to run their machines continuously, which is beneficial for their high-volume, high-production runs. In one week, this team was able to complete the same production capacity as what they were previously completing in double the time. Essentially, the addition of machine tending robots made it easier for this team to fulfill customer orders in a timely manner. As a result, they’re able to keep customers satisfied and boost not only their efficiency, but their profitability as well.
Thanks to new technological advancements, the manufacturing industry is making strides toward a more automated working environment. While automation isn’t a new idea by any means, the tools being introduced are playing a large role in how businesses operate to optimize their standard practices.
Machine tending is a vital process for virtually all industries. But, if you’re still relying on manual processes to get these tasks done, then you’re missing out on an opportunity to improve your standard operations.
Improving efficiency doesn’t mean you need to bring in new CNC machines in order to increase production. Instead, job shops can address the limitations created by machine downtime by improving the tools they already have with the addition of machine tending robots.
Robots introduce new levels of automation that can significantly enhance capacity, thus increasing throughput. And, Automation Within Reach has multiple machine tending robots available that are compatible with existing machines. Whether your operations require mill tending or lathe tending, AWR has a robotic automation solution that will work for you.
To learn more about the AWR product lineup and how our tools can help your business excel, get in touch with an automation expert today!