Articles

5 min read

Advice for Metal Fabricators: Consider a Cobot

A recent report released by the Department of Labor states that a record 4.4 million people quit their jobs in September 2021 as job openings remained unchanged at 10.4 million.  So, while there are plenty of available jobs, many companies are having a tough time finding workers.  This is particularly troubling for metal fabricators looking to keep up with increased demands that require skilled welders.“A huge factor right now is the lack of welders in the market and available to work,” says Gary Kowalski, regional sales manager, material joining sales team, FANUC America Corp. “Nobody can find welders to fill job openings.  Many companies are offering higher wages, shorter work weeks and other measures just to get skilled people in the door.” Speak with a FANUC Welding Cobot Expert, today! So, for the hundreds of companies struggling to keep up with their customers’ demands, robots and collaborative robots, or cobots, in particular, are the right answer.  But what about small to medium-size manufacturers that have not used robots in the past to tackle their welding operations?  These companies are looking for ease of use and speedy deployment.  Larger companies can afford to spend a lot of time to create a highly productive and focused system for a single type of part.  Smaller companies need to weld a wide variety of low-volume parts right now.It’s common knowledge that many simple manual welding tasks are the culprit behind repetitive motion injuries and downright boredom for skilled welders.  But, pop a cobot into the workcell, get it up and running in less than 30 minutes, and it’s ready to take on the job at hand. Welding cobots not only help reduce costs, but they allow skilled welders to focus on the complex jobs that require their expertise while maintaining quality welds.Welding benefits“FANUC has an automation solution for any size company – from small shops to large assembly manufacturers,” Kowalski says. “If the job is for a high-volume run, possibly an automotive part, FANUC’s traditional high-speed ARC Mate welding robots are well suited to produce as many parts as possible in the shortest amount of time.  But for low-volume, high-mix welding applications, the CRX cobot is a great fit.”The latest CRX welding cobot is quick to set up and easy for any skill level to operate. The CRX cobot welder can be programmed using a touchscreen tablet while the programmer moves the robot to the desired weld location on the part.“It’s really a short learning curve to get up and running quickly,” Kowalski says. “This includes the main feature of the CRX cobot, which is the quick teaching of simple welds.  It’s an intuitive process and an operator can learn to perform it almost immediately.  They just position the torch on the part, push a button, and that program is created.”It’s common knowledge that most cobots have a lightweight and compact design – but the CRX cobot offers more, including industrial ruggedness, reliability and minimal maintenance features.  In fact, the CRX can operate for eight years maintenance-free, which is a major advantage for companies looking to lower costs and increase productivity.A collaborative robot moves more slowly by design to accomplish tasks and adhere to safety requirements.  High-volume welding projects require the robots to move as fast as possible to make the most parts with the fewest robots.  These robots are usually equipped with rotating fixtures and automatically clamping end-of-arm tools that require safety barriers to protect people.  The collaborative robot works side-by-side with a worker at a table, without moving fixtures or clamps - in other words, just perfect for basic job shop welding but too slow for high-volume production welding.It’s really a short learning curve to get up and running quickly. This includes the main feature of the CRX cobot, which is the quick teaching of simple welds.The CRX welding cobot supports several of FANUC’s advanced features, including iRVision, which is a fully integrated visual detection system that enables robots to see, making production faster, smarter, and more reliable.“We have also released our advanced features from the ARC Mate robots to the CRX cobot, including Touch Sensing and TAST (Through-Arc-Seam-Tracking),” says Kowalski. “This allows us to cover a complete range of collaborative applications while maintaining an ease-of-use programming environment that the market is calling for.  When I talk with customers looking to automate a particular welding project, I suggest the CRX cobot as a great starting point.  As their business expands to the point that requires higher production rates, they can then easily add ARC Mates to tackle those jobs.”Since initially introduced to perform material handling, the CRX cobot continues to take on more applications, including welding, vision inspection, palletizing, machine tending, vision-guided pick and place, and sanding.  CRX cobot e-Learning training modules are available to help operators get up to speed very quickly.  There are currently eight online tutorials that cover a product overview with features, unboxing, and setup, three programming courses, and two iRVision courses.  More learning modules will be added as they become available.Watch the application videos and learn how the CRX cobot can help companies achieve higher manufacturing efficiency.See what cobots can do for your operation. Talk to our collaborative robotics specialists today. Get In Touch With Us Today  

Application:
Welding
2 min read

Fast, Easy, and Ready-to-Deploy Cobot Solutions

FANUC America’s new web tool allows customers to research ready-to-go collaborative robot solutions featuring FANUC’s reliable and efficient CRX cobots.

Application:
7 min read

Your Road Map to Pre-Engineered Cobot Systems

Unlock the potential of pre-engineered cobot systems to enhance automation in manufacturing. Now is the perfect time to invest in customized automation for your business.

Application:
7 min read

Choosing the Right Control Protocol Can Make Cobot Integration Much Easier

Even advanced automation systems need the right control protocol — like EtherNet/IP, PROFINET, Modbus TCP, or I/O Link — to ensure fast, reliable communication between devices and smooth integration across the production line.

Application:
6 min read

FANUC America Debuts New Food-Grade Cobot

Offering the longest reach and highest payload in its class, the new CRX-30iA food-grade collaborative robot supports efficiency and consistency across a range of food and beverage applications.

Application:
8 min read

Have You Considered Mobile Cobots for Machine Tending?

Companies all over the world are evaluating their production operations to determine how to increase productivity. That’s a key reason why the demand for robotics and automation is growing at a rapid pace.Mobile robots have become a popular solution for a variety of industries, including e-commerce, where the robot can move quickly from one location to another to pick products for order fulfillment. Now, many industries are looking at using cobots on a mobile platform to offset the shortage of skilled workers, improve productivity, meet critical deadlines, and maximize ROI.Companies that machine parts not only face labor shortages and productivity issues but are now challenged by customer demands to handle low-volume, high-mix work. A very flexible and safe solution is mounting a cobot to a mobile platform like an autonomous mobile robot (AMR). This type of mobile robot solution makes it easy for one worker to move the robot to different machines around the plant floor and quickly set it up for any number of tasks – a huge benefit that allows companies to meet their customers’ demands and, at the same time, save time and money. It also allows skilled employees to stay in the cobot’s work cell to handle other tasks while the cobot does the repetitive loading and unloading.Mobile Manipulator DemonstrationFANUC recently demonstrated flexible machine tending featuring its latest CRX-20iA/L cobot mounted on a platform. An OTTO 100 AMR docked under the platform was used to lift and transport the cobot to autonomously complete a variety of common tasks found in any job shop, including part kitting, washing and machine tending. This system, designed and built by Capriol (West Bloomfield, MI), is an excellent example of how a cobot’s capabilities can be expanded, turning it into a true mobile manipulator. wistia-player[media-id='bnc4gvehsp']:not(:defined) { background: center / contain no-repeat url('https://fast.wistia.com/embed/medias/bnc4gvehsp/swatch'); display: block; filter: blur(5px); padding-top: 56.25%; } Powerful AMRThe OTTO AMR, yielding about two hours of runtime, is used to power the equipment onboard the platform between the cobot and the AMR. Much more than a simple mechanical link between the two, the platform contains the necessary equipment to power the cobot with the AMR’s batteries, wireless communication equipment for the cell PLC and I/O connections for application-specific sensors.So, in this example, the AMR’s batteries last for two hours. At the two-hour mark, the AMR swaps places with another fully charged AMR. A stable secondary power supply (UPS) enables the cobot to finish its cycle, and the system continues to run with no lost productivity.Localizing with 2D VisionWhen using mobile manipulators, a docking station’s position and orientation must be verified every time using some form of localization to ensure repeatable robot motion. What can impact repeatability?When a mobile robot docks at a station, repeatability can vary by several centimeters.Since floors are not perfectly level, any small dip or bump can significantly change the position of the cobot’s end-of-arm tool.2D Vision can solve the issues within seconds. This is accomplished by adding a vision target (a camera calibration grid) to each station and teaching all the targets’ positions. When the mobile manipulator arrives at a station, a 2D camera takes several images of the target and calculates its position and orientation relative to the robot. This establishes the target’s position, and all subsequent robot motion at the station is just as accurate as when it was first taught.CNC ServicingThere are many ways for a CNC machine to communicate with a mobile manipulator. The recent demonstration attempted to mimic a human operator as much as possible, so vision was used for communication between the CNC and the rest of the cell.When the machine finishes a cycle, it opens the door and uses the stack light to indicate service is required. The mobile manipulator arrives at the machine and checks the light to confirm it’s ready. After completing tasks at the machine, the robot presses the cycle start button and checks the stack light a final time to verify the machine is running before it leaves the station.Another application might use networked communication to talk to the CNC machine, potentially yielding a more efficient solution. In this case, the CNC machine can signal when it is almost finished with a cycle, and a mobile manipulator can be dispatched early so it arrives right as the machining cycle completes, improving efficiency.Collaborative TechnologyThe CRX-20iA/L used on the mobile manipulator is a power and force-limited collaborative robot. The mobile manipulator system also has laser scanners mounted on two corners offering 360-degree coverage. These two safety-rated systems (the cobot and the area scanners) can be used together to achieve a safe system.For low-risk tasks, the FANUC cobot provides safe operation without the need for safety scanners. If higher speeds are required or the task is riskier, such as handling a sharp part, then safety scanners can be used to prevent the arm from moving when operators are near. The key here is flexibility - the power and force-limiting features of the cobot can be augmented by the area scanners to achieve a safe system in a way that makes sense for each unique application.  Mobile Robot NavigationThere are several advantages of utilizing an AMR like the OTTO 100 to transport a mobile cobot/manipulator, including:Flexibility to respond to unexpected obstacles by automatically rerouting around obstructions.Large wheels allow the AMR to travel over factory floors, even those that are cracked or have bumps.Straightforward route map setup – it takes just one manual drive around the site, and the AMR’s map is set. The map is then populated with stations, chargers, and other points of interest.OTTO’s robust Fleet Manager software enables everything from programming simple waypoints to defining complex factories integrated into building infrastructure. Changing machine location or workflow is as simple as adjusting destinations on the map – the AMR handles everything in between.Maximizing Return on Investment (ROI)Before investing in a mobile manipulator system, it’s important to work with a reliable automation supplier who will conduct a thorough review of your operation to be sure the automation is used efficiently. In the above example demonstration, a cobot performs different tasks at each station. An alternative and possibly more cost-effective approach might be to use fixed robots at each station to perform process tasks and only use the mobile manipulator to move parts between stations and fixtures. This keeps the mobile manipulator moving as much as possible, allowing it to service more stations versus using it to perform tasks at each station.Mobile machine tending is an investment that pays off in consistency and flexibility. Machine loading is performed with robotic precision and part throughput doesn’t change from shift to shift. Robots don’t attend meetings and they don’t mind working three shifts. Thinking long-term, a mobile solution is the most flexible: a rail-mounted robot may initially be faster, but changes are expensive and require significant rework. A mobile solution easily accommodates layout changes, expansions, and even complete workflow changes.Another way to look at ROI is employee satisfaction and retention. By automating the strenuous and repetitive tasks of loading and unloading CNC machines, you can reduce the risk of employee injury, making their jobs much safer. When your employees can focus on higher-value tasks, they will be more satisfied with their workplace, thereby decreasing turnover and limiting your need to specifically hire manual laborers in those positions.Future-Proof Your Factory with a Mobile Machine Tending SolutionWhen it comes to machine tending, there are always checks and balances to review before implementing any new equipment or processes. Thinking long-term, a mobile manipulator is a very flexible solution that can help you meet customer deadlines, maximize your productivity and help you overcome labor challenges.Imagine implementing a system like the one highlighted in this article to tend CNC machines, then a couple years later, an inspection station is required. With a mobile solution, this workflow change can be quickly implemented by programming the robot at the new inspection station and simply adding a destination to the map. Alternatively, if you are strictly a manual operation, major changes to the process would require additional manpower and scheduling – but what happens if you’re not able to fill the jobs? And, if a linear rail had been previously installed, an expansion may not even be possible – where would you find the additional floorspace?A mobile solution’s flexibility is its most important benefit and a key reason behind the growth of mobile robots in automation. If you’re considering automating one or more machining process, you may want to take a closer look at a mobile solution. For more information, contact FANUC.See what cobots can do for your operation. Talk to our collaborative robotics specialists today. Get In Touch With Us Today  

Application:
Machine Tending/Part Transfer
4 min read

Can Cobot Packaging Help Your End-of-Line Operations?

If you’re challenged with labor issues in your packaging and palletizing area, you’re not alone. These applications are often tedious and can lead to repetitive motion injuries. In a tight job market, it’s especially difficult to fill jobs that people consider dull and strenuous. Now more than ever, companies are looking for automation solutions that will allow them to resolve labor issues and increase their flexibility to quickly adapt to market demands.Can cobot packaging help your end-of-line operations? Here are a few areas to consider:Cobots for Case ErectingSome companies have very limited space, or they have "oddball" box sizes that can’t be erected with a traditional case erector. In these instances, using a collaborative robot to erect cases is an ideal solution because they are not only flexible but also quick to implement and easy to program. So, when box sizes change, it’s a simple program adjustment, and the cobot is back up and running in a few minutes. wistia-player[media-id='whqs7k36mg']:not(:defined) { background: center / contain no-repeat url('https://fast.wistia.com/embed/medias/whqs7k36mg/swatch'); display: block; filter: blur(5px); padding-top: 56.25%; }  Cobots for Case PackingFor low- to medium-volume production, companies continue to use people to pack products into cases, which is another good example of a job for cobot packaging. Space and flexibility are often major concerns in these applications, so the fact that a collaborative robot does not require safety fencing makes them very appealing. In addition, because programming is so easy, you can cross train a variety of employees to run the cobot - so if someone calls in sick, another person can step in and get the job done on time.Cobots for PalletzingStacking boxes all day is monotonous, and employees are very prone to repetitive motion injuries. A collaborative robot palletizer is a great solution to this problem, and it allows manufacturers to redeploy their workforce to perform other roles in their facility.What about palletizing speed?Speed can be an issue for cobots, but the main limiting factor is the combination of speed and load capacity. Based on the packaging cobot’s capacity, you can address the speed issue by picking multiple products at one time. For example, if you have boxes that weigh four pounds coming on a line at 16 boxes per minute, you can potentially pick and palletize four boxes at a time.What about company size?Even large companies have lower-rate production lines. For example, a large food or beverage manufacturer may have a number of high-speed lines for their well-established products, but they also have slower, manual lines that produce new/emerging products. The same can be said for just about any industry. All manufacturers are facing the same labor issues regardless of their size, and cobots for packaging may be the solution for many manufacturers.FANUC CRX CobotsFANUC recently expanded its line of CRX cobots, including the new CRX-30iA, which offers a long reach of up to 1,889mm, a 30 kg payload,and is both flexible and scalable to handle a wide range of palletizing or de-palletizing processes, including mixed cases, making it a great contender for manufacturers seeking cobots for packaging. wistia-player[media-id='9frw8bhzun']:not(:defined) { background: center / contain no-repeat url('https://fast.wistia.com/embed/medias/9frw8bhzun/swatch'); display: block; filter: blur(5px); padding-top: 56.25%; }  All CRX cobots are extremely robust and able to run for up to eight years without maintenance. In addition, interactive programming enables users to teach points using hand guidance or a tablet interface with drag-and-drop icons.In addition, the CRX series supports several of FANUC’s advanced features including iRVision®, and is a perfect fit for any company looking to achieve higher efficiencies – even those that have yet to use their first robot.Time to Automate? Consider a FANUC CRX CobotFANUC understands that manufacturers and co-packers may not have enough labor to run every dedicated line simultaneously. That’s why our CRX cobots have become so popular—they use standard 120v power, have a small footprint that fits into tight spaces, and can be easily moved or rolled from line to line to take on new tasks in a matter of minutes.Automating end-of-line applications with cobots allows you to redeploy workers to help solve the current labor shortage. Instead of performing repetitive tasks, workers can take on more challenging, complex, and rewarding jobs that only humans can do.If you’re looking to automate packaging with a cobot, trust FANUC. Our cobots are based on a long history of reliable, high-quality automation products supported by the industry’s top team of automation experts.See what cobots can do for your operation. Talk to our collaborative robotics specialists today. Get In Touch With Us Today  

Application:
Packing
2 min read

Cobots Help Last Arrow Manufacturing Boost Productivity

Last Arrow Manufacturing, an Ohio-based contract manufacturer, needed a flexible automated solution to take on simple and repetitive welding projects to free up their skilled welders to do jobs that required more expertise. After trying a variety of automation options, they chose the FANUC CRX welding cobot and haven’t looked back. Since implementing cobots, Last Arrow has experienced a very quick uptick in business, a high level of employee satisfaction, improved flexibility, and higher profits. wistia-player[media-id='aeoo3d13cx']:not(:defined) { background: center / contain no-repeat url('https://fast.wistia.com/embed/medias/aeoo3d13cx/swatch'); display: block; filter: blur(5px); padding-top: 56.25%; } FANUC Cobots are the right choice for your welding processesWhy FANUC? Our cobots are easy to set up, program, and redeploy and include FANUC's intelligent welding options, which our customers have come to expect, including iRVision, Thru-Arc Seam Tracking, and Touch Sensing. Find out more today! FANUC CRX CobotsWhen it comes to your welding operations, our all-new CRX cobot is a complete game-changer, allowing you to shift from high-mix low-volume to low-mix and high-volume tasks with ease. In addition to being easy to set up and program, the FANUC CRX cobot is the only collaborative robot on the market with FANUC reliability, offering 8 years of Zero Maintenance on Motors, Reducers, Sensors, Cables, and Grease.See what cobots can do for your operation. Talk to our collaborative robotics specialists today. Get In Touch With Us Today  

Application:
Welding
4 min read

Will a Robot or Cobot Work for Your Small to Medium Shop?

Today, small and large manufacturing plants in North America are ramping up production, and many are considering using robots for the first time. Why now? Some shop owners are having a difficult time finding skilled workers, and others who already have a full staff continue to look for ways to keep social distance measures in place and meet increasing customer demands. Whatever the situation, a production manager must first ensure a safe work environment. If the plans call for traditional industrial robots, there’s safety fencing and sensing devices to consider, along with robot software to prevent contact with people (better known as speed and separation monitoring). Another great option to consider is a cobot or collaborative robot, which is power and force limiting by design. Either type of robot can be highly effective for part transfer and machine tending, as long as everyone involved follows the proper safety protocols and the robot meets your payload and speed requirements.How do you decide what type of robot will work best for your shop?Standard industrial robots can operate near workers as long as the appropriate sensing hardware is used. Traditional robots are typically the best choice when people only need to access the work cell infrequently – perhaps just every few hours to reload raw materials or check critical part features. Cobots on the other hand, such as FANUC’s latest CRX Collaborative robot, are ideal for working alongside people to assist with the dull, dirty and dangerous jobs while the operator is there to perform tasks that require human skills. The Rise of Flexible AutomationWhatever choice you make, robots and cobots have come a long way in the last decade. Gone are the need for huge conveyors and fixed guarding that take up a big chunk of floor space. In most cases, today’s robots are able to locate parts from any orientation – often with the help of 2D or 3D robot vision, such as FANUC’s integrated iRVision. Vision enables the robot to pick randomly oriented parts from a bin, tote, or any type of container. Once the part is picked, the robot can reorient it as needed and quickly load it to any type of work holding device. When that portion of the operation is complete, the robot transfers the part to the next task.  Another flexible robot solution designed to help manufacturers deal with capacity shortfalls and labor shortages is mounting a robot to a mobile platform – much like Acieta’s FastLoad CX1000. This type of mobile robot solution makes it easy for one worker to move the robot to different machines around the plant floor and quickly set it up for any number of tasks – a huge benefit that allows companies to meet their customers’ demands and save time and money.Cobots on the other hand, such as FANUC’s latest CRX Collaborative robot are ideal for working alongside people to assist with the dull, dirty and dangerous jobs while the operator is there to perform tasks that require human skills.Robots for High-Mix, Low-Volume ProductionEven though today’s robots and cobots improve throughput, increase flexibility to tackle multiple operations, and reduce operating costs, there’s still a wide gap between machine tools that are being ordered and those that are automated with robots.  The term “lights out” has been a far-reaching goal for some manufacturers – at least for a portion of their production operations.  Typically, robots are used for large batch/high-volume runs at night with less people, while the small batch/low-volume jobs are processed during the day with more staff available.  In the last few years; however, there’s a growing number of robotic solutions able to handle the low volume, high-mix work that is typical in smaller companies. In these cases, the robot handles different sized parts in a family or group of parts, allowing for fast changeover when the parts change. This technology continues to improve.Robotic machine tending has revolutionized manufacturing, allowing companies to increase their overall equipment effectiveness. Once the robot loads a machine, it can perform secondary processes like deburring, cleaning, inspection, and much more, utilizing the same gripper or a quick tool changer if needed.  What challenges do you face that are prompting you to consider automation?Whether you’re looking to overcome labor concerns or ways to address manufacturing growth, or all of the above, let’s talk about how FANUC can help. Contact us today, and we’ll schedule a time to review your operation to understand what robot or cobot will work best for you.See what cobots can do for your operation. Talk to our collaborative robotics specialists today. Get In Touch With Us Today  

Application:
2 min read

7 Things You May Not Know About Cobots

Collaborative robots – or cobots – provide a number of advantages and ways to ensure you get a break on the job. The use of cobots is on the rise, and people in the workforce will benefit. wistia-player[media-id='okgx0p19ff']:not(:defined) { background: center / contain no-repeat url('https://fast.wistia.com/embed/medias/okgx0p19ff/swatch'); display: block; filter: blur(5px); padding-top: 56.25%; } Here are seven things you may not know about cobots:1.  They offer increased flexibility – Because cobots can be easily taught new tasks, users have the flexibility to move them as needs change.2.  They fit into small spaces – Sleek and ergonomic designs include a lightweight and compact arm that fits in virtually any floor space configuration.3.  They are easy to install – Users - even those with no experience using a robot can set up a cobot and get straight to work.4.  They are easy to program – Ideal for first-time users. FANUC’s CRX model cobots use manual guide programming and a new icon-based, drag-and-drop teach pendant user interface. 5.  They are intelligent!  Equipped with iRVision and application software, FANUC cobots can quickly locate parts, making them great for robotic picking & packing, machine load/unloading, and more.6.  The gentlest touch stops collaborative robots because safety comes first.7.  Collaboration is the key – Cobots were designed to work with people, not replace them.  They make work easier, so employees can complete work more quickly, focus on multiple tasks, and even take a break.Learn how cobots can revolutionize your operation. Talk to our collaborative robotics specialists today. Get In Touch With Us Today  

Application:
2 min read

The Four Types of Collaborative Robot Operation

Collaborative robots are becoming increasingly popular in manufacturing. As more companies adopt automation, there are many tasks identified that require people to work in collaboration with a robot. Let’s examine the four types of collaborative robot operation:1. Power and Force Limiting cobotsPower and force-limited cobots are likely what most people think of when they hear the term collaborative robots. They are designed to sense contact with people and cease operation, eliminating the need for safety barriers. They are best suited for smaller applications.For the three other types of collaborative operation, any industrial robot can be integrated with safety devices to become “collaborative.”2. Safety Rated + Monitored Stop cobotsSafety-rated + monitored stop cobots detect when a person enters a designated area and stop operating until they leave that shared workspace, eliminating the need to restart a robot with the push of a button. Once the person leaves, the robot automatically continues its task. These are generally used when there’s not as much interaction between a person and a robot.3. Speed and Separation cobots (also called “fenceless”)Speed and separation cobots work well when there is not much interaction with a person, but a person needs easy access to the robot. Safety laser area scanners are commonly used to set up zones near the robot’s workspace.  When a person approaches the robot, its movements slow down and then stop if that person gets within reach of the robot’s workspace. As soon as the operator moves out of the robot’s workspace, the robot automatically resumes normal speed.4. Hand Guiding cobotsFinally, hand-guiding cobots have a safety-rated device attached to the end of the robot’s arm to allow a person to guide or move the robot around manually.  Hand guidance is often used to quickly and easily program new robot paths and positions by hand. It’s also ideal for mobile applications where the cobots move between stations and require re-training to accomplish different tasks, and when the cobot needs to be reprogrammed frequently for a new job.See what cobots can do for your operation. Talk to our cobot specialists today. Get In Touch With Us Today  

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