XavierThe Basics of Robotic Machining
The benefits of robotic machining are clear, and you’ve probably read our guide to choosing the right robotic machining for your needs. But what’s next?
In this guide, we’ll walk you through everything you need to know so you can get up and running with a robot as smoothly as possible. By the end, you’ll have the know-how to start enjoying the benefits of robotic machining on your shop floor.
1.What to Consider Before Installing a Machining Robot
There are a few key things to consider before purchasing and installing a machining robot.
Start by assessing your current machining process and identifying any potential roadblocks to automation. Look for bottlenecks, hazardous areas, and tasks that require human dexterity. You may need to modify your workflow, equipment, or facility layout to accommodate certain robots.
In terms of facility layout, consider which robot will fit your needs. Options include articulated, SCARA, and Delta robots, which are fixed to a single point on the factory floor. If you need a Cartesian robot, it’s important to note that these robots are typically fixed to a ceiling gantry.
When making your selection, consider the payload capacity, reach, speed, and precision your machining operation requires. For more details, see our guide to buying a robot for machine operations here.
One challenge you need to consider is the flow around the robot. For example, how will the blanks be delivered to the robot for machining? Do you need a conveyor or similar system to move the parts to the robot? The decision you make will not only affect your initial investment, but also your risk assessment of operating the robot around employees.
Another challenge you may encounter is robot programming. If you are new to the world of robotics, you will need to look for ways to simplify programming, such as choosing a robot with a graphical interface rather than one that requires an expert to code line by line. It is best to start with basic movements, functions, and standard tasks, then gradually increase complexity through iterative improvements.
To keep your machining robot in working order, you will need to introduce new tasks into your routine maintenance routine, such as lubricating joints, tightening bolts, and checking for signs of wear or damage. With proper care, machining robots can provide many years of reliable service, and your manufacturer will usually be able to provide you with an expected service life in operating hours.
2.Perform a risk assessment of the work area for robotic machining
Before signing a contract for a new machining robot, it is essential to perform a comprehensive risk assessment of the work area. This will identify any hazards and allow you to implement appropriate protective measures.
First, assess the space where the robot will be operating. Make sure there are no hazards such as uneven floor tiles or low-friction materials that could cause the robot to be unstable. Check that the robot has a solid, level base to prevent tipping or overturning.
It’s also important to consider the specific tasks the robot will perform. Will it handle sharp tools or heavy objects that could fall? If so, install guarding, such as fences and drop zones, to contain loose items. Consider the robot’s maximum reach and any pinch points that could catch body parts or clothing during movement, so that barriers are placed throughout the range of motion.
It may be necessary to install an emergency stop button so that the robot can be quickly shut down if necessary. Create separate spaces for human workers and robots, and only allow entry when the robot is fully shut down.
If the robot will be working around humans, consider choosing a collaborative robot with built-in safety sensors and collision detection. Train workers on the correct procedures to safely load, unload, and clean the robot.
Once the robot arrives, test the risk assessment with a few trial runs. See if any other hazards arise or if any guarding needs to be improved, and continue to review the risk assessment regularly to ensure the highest safety standards.
3.Programming Robotic Machining Assistants: Common Pitfalls and Tips
While programming is a complex topic, it pays to know some basic pitfalls and tips—especially if you’re going to use a robot that doesn’t have code programming capabilities.
Here are some things to keep in mind:
1) Start Simple
Don’t try to program complex mechanical operations from the beginning. Start with basic pick-and-place tasks to get familiar with the robot’s programming interface. Then build up to more complex programs step by step. This will help minimize frustration and errors.
2) Use Simulation Software
Simulation software allows you to virtually program and test your robot before deploying it to the shop floor. This helps identify programming issues and potential collisions early, without wasting time and materials or damaging the robot.
3) Plan for Safeguards
Always build safety precautions into your programs, such as emergency stops, speed reductions, limited work ranges, and collision avoidance. Unexpected collisions can cause expensive damage and costly downtime, or even injure your team members. It’s much easier to build safety measures into your programs from the beginning than to retrofit them afterward.
4) Get Input from Operators
Talk to your machine operators to understand the best way to integrate your robot into your existing processes. They know the ins and outs of your shop processes and can offer valuable advice on how to maximize productivity and safety. Be open to suggestions for improving your procedures.
5) Back up your programs regularly
Back up your robot programs regularly to prevent data loss or corruption. Nothing is more frustrating than having to reprogram your robot from scratch due to a system failure. Back up your programs to separate storage devices as well as cloud services for redundancy. Make sure you understand your “disaster recovery” processes to avoid downtime.
4.Introduce your workers to robotic machining
Combining human and robotic machining requires careful planning and coordination. As a shop owner, you need to determine how to best utilize both human and robotic labor without sacrificing productivity or job satisfaction
Cross-train your employees in robot operation and programming. This allows them to better understand the robot’s capabilities and limitations and troubleshoot any issues. Often, one employee can multiply productivity by overseeing multiple robots.
In the beginning, have the robot handle repetitive, monotonous tasks, such as loading and unloading, which frees up employees to do more skilled work.
As employees become more comfortable with using the robot, you can gradually increase the robot’s responsibilities. Educating employees about what robots are good at and what they are not good at can help them understand the robot’s place in the company.
Promote collaboration and encourage employees to work with the robot, not against it. Explain how robotic machining can benefit the entire company by improving efficiency and quality.
Ask workers to provide feedback on optimizing robot programs and work cell layouts. When employees feel successful with the robot, they will be more willing to adapt to changes in workflow and job responsibilities.
5.Best Maintenance Tips for Machining Robots
To keep your machining robot in top working condition, you need to adjust your maintenance procedures. Here are some items we recommend adding to your maintenance checklist.
Perform a routine inspection of the robot at least once per shift to check for any signs of damage or wear. Check for loose wires, leaks, or loose parts. Given the high forces involved when moving a robot, small problems can quickly turn into major damage.
Lubricate moving parts such as joints and bearings. Follow the recommended lubrication schedule provided in the robot manual. Note that the end effector attached to the robot will have its own lubrication schedule. Proper lubrication prevents overheating, reduces friction, and extends the life of components.
Tighten loose parts, as vibration and repetitive motion can cause bolts, screws, and other fasteners to loosen over time. This helps ensure continued safe operation and precision.
Clean your robot regularly, as dust, debris, and dirt buildup on the robot can affect cycle time and lifespan. Pay special attention to joints, seams, and crevices where material can accumulate. For stubborn stains, check with the robot manufacturer for appropriate cleaning materials.
If your robot appears to have lost precision or accuracy, calibrate it when necessary. Recalibration involves adjusting sensors and controls on the robot or end-of-arm tooling to restore proper function. This should be a regular maintenance task to avoid potential safety issues or further degradation of the programmer on your team.
6.Robotic Machining FAQs
Robotic machining can seem complex, but many of the most common questions have simple answers. Here are some FAQs to help you navigate the process.
1) How much space does a robot need?
A robot’s “footprint” refers to the floor space it requires to operate, which is typically 4 to 16 square feet. You’ll also need additional space for loading and unloading parts and for maintenance.
2) How difficult is robot programming
Modern robots are designed to be easy to program for basic tasks. You can start programming with simple no-code programming software and basic training. For more complex jobs, you may need an experienced robot programmer. Some robots use an intuitive teaching pendant with step-by-step programming instructions.
3) How safe is the robot
If installed and programmed correctly, industrial robots have an excellent safety record. However, there are risks associated with contact with moving parts. Risk assessments help identify hazards and determine appropriate safety mechanisms such as protective barriers, emergency stops, and operator training. Proper safety procedures must always be followed. Collaborative robots are generally the safest choice when working around humans.
4) What maintenance do robots require
Robots require regular inspection, lubrication, and replacement of parts. Motors, joints, and end effectors generally require the most maintenance. It is also important to clean up debris and dust every day. Following the manufacturer’s recommended schedule will minimize downtime and keep your robot in good working order.
7.Summary
Now you have everything you need to get started with robotic machining. You’ve learned how to select the right robot for your needs, evaluate how it will fit into your current setup, ensure everyone’s safety, program the robot to do what you want it to do, keep it working properly, and have your employees and robot mechanics collaborate.
Whether you need a robot to load and unload parts, move materials, or perform inspection and sorting, there are a variety of robotic arms that can get the job done efficiently and cost-effectively. The key is to determine the tasks you need to automate, which machines the robot will interact with, and the speed, payload, and precision required.