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Assembly line robots perform the same job repeatedly at a production line but provide flexibility to manufacture items that differ in shape, size, and weight. They come in various types.
Articulated robots
Articulated robots have rotary joints. They are available in different sizes and are manufactured with up to ten or more interchangeable joints. The multi-joint characteristic gives the robots an assembly line movement comparable to the human arm, allowing them to easily lift and maneuver heavy and oversized objects. They are frequently used for welding, assembly, packaging, and material handling.
Collaborative robots
Collaborative robots, or cobots, work together safely with human workers on an assembly line without needing safety cages. Their ability to share a workspace with people makes them ideal for roles where close cooperation is essential. Due to their lightweight construction, they can easily be relocated to other assembly lines where required. Typical tasks for cobots include assembly, quality inspection, picking, packing, and palleting.
Delta robots
Delta robots have a spider-like parallel linkage mechanism. They consist of a base connected to three separate arms or fingers, which move in a synchronized manner to lift and move objects. The independent movement of the arms allows for fast and precise motion, enabling smooth acceleration and deceleration. Delta robots excel at high-speed picking and placing, palletizing, packaging, assembly, and sorting tasks.
Gantry robots
Also known as Cartesian robots, Gantry robots have a box-like structure that moves on a rail system. Assembly lines use them in material handling to pick and place products, load and unload machinery, and facilitate assembly tasks. They are particularly suitable in scenarios where heavy items need to be moved over long distances accurately.
Hexapod robots
A hexapod robot has six legs. They are also called six-legged robots, and they offer a high degree of freedom and maneuverability on an assembly line, making them an excellent choice for off-road and rough terrain applications. Their robust construction and versatility also suit them for military, medical, and robotics research.
SCARA robots
The Selective Compliant Assembly Robot Arms (SCARA) robots have an upward bending joint assembly and feature a robot standard for high-speed assembly and precision tasks. Their design provides horizontal flexibility and vertical rigidity, making them ideal for assembly applications that require high speed and precision, such as electronic component assembly, inspection, and packaging.
The specifications of an assembly robot vary depending on its type and application. Here are some general specs for robots:
Payload Capacity
This is the maximum weight that a robot arm can handle when lifting and moving objects. It varies by robot type and construction. Heavy-duty robots have high payload capacities that can handle weights of over 1000kg. On the other hand, lightweight robots have lower payload capacities that typically range from 1kg to 50kg. For instance, a heavy-duty SCARA assembly line robot will have a payload capacity of over 1000kg. However, a lightweight collaborative robot will have a payload capacity of about 20kg.
Reach
Robot reach is the distance a robot arm can stretch from its pivot point to the end of its gripper. Like the payload capacity, the robot reach varies depending on the robot type. An industrial cartesian robot has a reach of about 1.5 meters to 2.5 meters. On its part, a SCARA industrial robot is designed for horizontal assembly tasks. It has a short reach of between 0.3 meters and 1 meter. Collaborative robots have flexible reach that allows them to work seamlessly alongside humans.
Joint Configuration
A robot arm has different joints and linkage combinations. These include Cartesian, SCARA, Spherical, Cylindrical, Parallel, and Articulated Joints. Each joint configuration works well in a specific task or application. For example, an articulated robot with six joints will mimic the movement of a human arm. It is suitable for assembly tasks that require high flexibility and dexterity in tight spaces.
Speed
Robot speed is the rate at which it moves to complete a task. It is measured in units of time, such as seconds or milliseconds, for completing tasks like picking and placing items. An articulated assembly line robot is faster than humans. It is capable of picking and placing objects in about 0.3 seconds. Also, a delta robot is one of the fastest robots on the market. It can complete picking and placing tasks in about 0.1 seconds.
To keep the assembly line robot in good condition, employers should schedule regular maintenance checks. Some benefits of maintenance include improved performance, reduced downtime, and prevention of unexpected breakdowns. Users should also take the following proactive measures to extend the lifespan of their robots.
Cleaning an industrial robot involves removing debris, dust, and contaminants that accumulate over time. This process keeps the robot free from clogs and blockages. When cleaning the robot, focus on frequently touched surfaces like grippers and visors. When done, inspect the robot for any signs of damage or wear. Then, use a clean, dry, lint-free cloth to wipe it off.
During operation, the moving parts of an assembly line robot are subject to constant friction and wear. Lubrication forms a protective layer to minimize wear and tear. This process allows the robot to move freely and smoothly. To lubricate the moving parts of the robot, identify the points that need lubrication. They may include joints, rails, bearings, and sliders. Then, apply an appropriate lubricant to each moving part. Wipe off any excess lubricant that may attract dust and dirt.
Manufacturers of assembly line robots often release software updates to enhance their performance. Updating the robot ensures it benefits from the latest features and capabilities. It also allows the robot to stay protected against known security vulnerabilities. So, find out if there are any available software updates. Then, back up the robot’s system before applying the updates. Finally, follow the instructions provided by the manufacturer to apply the updates safely.
Robotic assembly lines have a variety of use case scenarios as per different industry requirements. Below are a few:
Car assembly
Robots are widely used in the automobile industry for car assembly. They assist in a variety of tasks such as welding, painting, and installing parts like windows and dashboards. One key advantage of these robots is that they can fulfill customized demands at an ideal speed while being cost-effective. Assembly line robots also ensure accuracy and guarantee standardization. They can repeat the same action thousands of times without making an error. The robots also improve overall productivity. This is because while they are assembling one car part, another robot can assemble another car part simultaneously.
Packaging and Palletizing
Robots are widely used for packaging and palletizing products in different cartons. They assist in sorting, stacking, and organizing products onto pallets. Packaging robots also help in wrapping and sealing products to ensure safe shipment. Like most assembly robots, these specialized robots improve efficiency and productivity. They do so by ensuring and enabling rapid and precise packing and palletizing of products.
Electronics Manufacturing
Robots are used in electronics manufacturing to assemble and handle delicate electronic components. They ensure accurate placement of components onto circuit boards. They also help in soldering components, installing connectors, and assembling intricate electronic devices like smartphones, tablets, and computers. The robots ensure a high-level of precision required in electronics assembly. They guarantee efficient handling of fragile electronic components to minimize damage. Assembly line robots also increase speed and efficiency in the production process.
Food Processing and Handling
In the food industry, robots are used for food processing, packaging, and handling tasks. They assist in sorting, cutting, packaging, and palletizing food products. Robots designed for food processing typically have specialized grippers and tools to handle and process various types of food. They operate in conditions that meet all sanitary standards specified. Using robots in food processing minimizes the chances of contamination. They also ensure consistency in food production. These assembly line robots guarantee improved efficiency and productivity in food processing lines.
Consider flexibility and scalability:
Businesses should look for robots that can handle different types of products and be easily reconfigured as production needs change.
Choose robots that are easy to integrate:
Look for robots with standard interfaces and compatible communication protocols with existing assembly line systems.
Focus on user-friendly programming:
Selecting robots that offer intuitive programming environments and simulation tools can streamline the programming process and reduce the time needed to train operators.
Consider safety features:
Evaluating the safety features of potential assembly line robots, such as collision detection and emergency stop systems, is essential to ensure they meet safety standards and can operate alongside human workers safely.
Think about cost and ROI:
Consider the total cost of robot ownership, including initial investment, maintenance, and operating costs. Assess the potential ROI in terms of increased productivity, efficiency, and cost savings over the robot's lifespan.
Investigate the reputation of the supplier:
Choosing a robot from a reputable supplier can help ensure the quality and reliability of the robot, as well as the availability of support and spare parts in the future.
Q1: What jobs can an assembly robot do?
A1: An assembly line robot can assist with product inspection, product assembly, packaging, quality control, and product labeling.
Q2: What are the advantages of assembly line robots?
A2: They can improve production speed and volume, reduce the cost of labor, and produce consistent and accurate results. They can also minimize workplace injuries.
Q3: What are the types of assembly robots?
A3: The main two types of assembly robots are a Cartesian robot assembly and a Delta robot assembly. Those are followed by many others, such as polar robots, cylindrical robots, spherical robots, etc.
Q4: Are assembly robots affordable for small businesses?
A4: The cost of robot arms for assembly lines can vary depending on the size and functionality. Industrial robots are often a big investment. However, they can significantly improve production efficiency and reduce long-term operating costs, making them a worthwhile investment for many businesses.
