How to Select the Best Industrial Robot for Manufacturing Applications

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As robotic technology continues to advance, an increasing number of manufacturers are integrating industrial robots to automate tasks that are either repetitive or hazardous for human workers, or that cause bottlenecks in the production process. These robots are capable of taking on the workload of tasks that would otherwise require significant human effort, reducing both the risk of injury and enhancing operational flow.

Robotic automation not only significantly increases productivity and efficiency, it also enhances product quality while improving safety across various manufacturing sectors. However, the wide array of available options can make the selection of the right robot somewhat daunting. This article aims to delve into the different types of robots commonly employed in manufacturing environments and outline key criteria to consider in order to select the optimal robot for your manufacturing needs.

Common Industrial Robots and Applications

When most people think of robots, they may envision fictional characters like Rosie from the Jetsons. However, today's industrial robots are far from quirky; they are meticulously engineered with distinct features and specifications tailored for executing demanding manufacturing tasks efficiently. The five predominant types of industrial robots utilized in manufacturing are:

1. Cartesian Robots: These robots utilize three prismatic joints enabling linear motion along the X, Y, and Z axes. Many models include an additional wrist joint for rotational mobility. Renowned for their precision and ability to carry heavy loads, Cartesian robots are typically mounted overhead, which maximizes floor space and accommodates various part sizes. They are straightforward to operate and customize, making them ideal for applications such as pick-and-place, loading and unloading, material handling, and assembly. However, they face limitations when maneuvering around obstacles and are less suited for dirty environments due to their exposed sliding mechanisms.
2. SCARA (Selective Compliance Assembly Robot Arm): SCARA robots are designed with two parallel joints permitting lateral movement within a selected plane. The vertical rotary shafts paired with horizontal movement on the arm enable SCARA robots to deliver high-speed precision, rendering them excellent for assembly, packaging, and machine loading tasks. Their compact design and lightweight structure make them ideal for vertical assembly jobs, although the fixed swing-arm configuration may impede their ability to maneuver around objects in tight spaces.
3. Delta Robots: Featuring parallel joint linkages affixed to a stationary base positioned above workspaces, Delta robots excel at high-speed, intricate movements. They are particularly effective for rapid pick-and-place operations in sectors such as food processing, pharmaceuticals, and electronics. The lightweight arms allow for swift actions involving light loads, making them favorable for tasks requiring delicate handling.
4. Articulated Robots: Resembling the human arm in movement and structure, articulated robots have a range of two to ten rotary joints. This joint structure allows exceptional versatility and reach, making them indispensable in various applications, including welding, material handling, and automotive assembly. They can navigate constrained environments with ease due to their flexible design, though they might not achieve optimal speeds for high-speed tasks.
5. Collaborative Robots: Known as cobots, these robots are engineered to operate alongside human workers safely. Their design minimizes the risk of injury, even when they accidentally come into contact with humans. Cobots are adept at tasks like pick-and-place and quality inspection, making them suitable for environments where interaction with human operators is unavoidable.

Selection Criteria

The diverse robotic technologies available enable manufacturers, regardless of size, to benefit from enhanced efficiency, quality, and safety; however, selecting the right robot can be a complex process. The ideal robot not only enhances productivity and aligns with budget considerations but also meets the specific requirements of the task, including spatial and safety standards. Consider the following criteria when making your selection:

• Application Details: Defining the robot's intended function and placement is crucial. For instance, in environments shared with humans, collaborative robots are ideal, while SCARA robots fit well for tasks in compact areas.
• Required Reach: Understanding the robot's range of motion is essential. This includes both vertical and horizontal reach, which can significantly influence the choice of robot based on operational requirements.
• Robot Payload: Always consider the maximum load capacity, inclusive of the robot's end effectors and the items it will handle.
• Number of Axes: The flexibility offered by the number of axes is critical. While applications require specific axes, having additional axes may facilitate future expansions.
• Running Speed and Travel: Assess the required speed and operational distance the robot needs to cover as this relates directly to task efficiency.
• Repeatability: The consistency with which a robot can perform a task repeatedly is fundamental, particularly in high-precision applications like electronics assembly.
• Space and Footprint: Evaluate the physical space available for the robot; limitations could dictate the robot type needed.
• Robot Body Weight: Understanding the robot's weight aids in ensuring proper mounting and support to prevent any operational hazards.
• Protection Class: Depending on the nature of the tasks, the robot might need specific protective measures, particularly in industries dealing with sensitive items.
• Risk Assessment: A thorough risk assessment will ensure that all safety considerations are addressed, particularly in environments with human interaction.

The selection criteria discussed serve as a useful framework when researching the most suitable industrial robot for your application. A well-chosen robot should not only meet the required performance metrics but also align with safety and spatial constraints within your facility.

For assistance in identifying the optimal robot technology for your application, please contact JHFOSTER.

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