Conveyance Systems in Robotics Maximize Efficency

At a Glance:

Speed and positioning can now be controlled independently.
Coordinated motion with robotic arms streamline efficiency.
Linear motion and magnetic propulsion are leading the design change.
The role AI will play in conveyor design has yet to take shape.

As industries move toward using more automation, conveyance systems in robotics are helping manufacturers change the way they handle workflows and increase operational efficiency. Solutions that integrate high-speed pallet-based systems and advanced materials are some of the advancements seen in today’s fast-paced manufacturing and production environments.

To learn more about the advancements being made with conveyance systems, Machine Design reached out to Bosch Rexroth’s John Atchison, product manager, high-speed smart conveyance, and Bill LeAnna, sales product manager, transfer systems, for some insights.

Editor’s note: The following Q&A may have been edited for style, clarity and length.

Machine Design: What are the key principles of conveyance systems in robotics and how do they differ from traditional conveyor systems?

John Atchison: The ability to control speed and positioning independent of traditional stop gates allow for flexibility in the process of automation.

Bill LeAnna: Conveyor systems in robotics are usually pallet-based systems and are required to have high accuracy and repeatability where the pallets come into the robotic process station. In addition, speed and take time are crucial to maintain proper line throughput. Traditional conveyor systems are normally used to move parts or finished goods in a transportation mode where robotic processing is not used.

Modern high-speed conveyance solutions such as the ctrlX FLOW are pushing the boundaries of speed and precision within manufacturing.

MD: Please explain the role of sensors and feedback mechanisms in automated conveyance systems.

JA: By having a sensor system that acts similarly to an encoder, the real-time position and control characteristics are magnified, thus allowing total control of a process and independent control of multiple moving agents.

BL: Sensors and other feedback devices like RFID are used to provide information to the conveyor control system. This information is used for decision-making when moving pallets through the process stations. The feedback from the RFID systems is used as a verification that a pallet has been processed through all the required stations.

MD: In what ways can conveyor designs be integrated with robotic arms for more efficient operations?

JA: Coordinated motion with robotic arms allow processes to continue through a work cell more efficiently. Less time working on the task allows for smoother operations.

BL: Robotic arms or multi-axis Cartesian systems are usually combined with conveyor systems and allow for incoming part placement, dispensing of adhesives or sealants, or for several other functions like removing completed assemblies.

Pallet-based conveyors like this TS 2 conveyor remain fundamental in helping manufacturers transport objects. Also, there’s a trend to move heavier items at faster speeds.

MD: What are some common challenges in integrating conveyance systems with existing automation processes, and how do you overcome them?

JA: Smart conveyance systems allow processes to be rethought. No longer are you tied to the point-to-point sequential process of the past 100 years. Getting people to see past those challenges and think in a different light is one of the biggest hurdles. No longer is the traditional conveyance something you build around; now the smart conveyance system is the controls architecture in which the process is defined.

BL: Some automation processes require access to all sides of an incoming pallet. In some cases, we provide Lift Rotate Units (LRUs) that allow the payload and pallet to be rotated in 90-deg. increments. In other applications, the payload may need to be completely flipped from top to bottom. We integrate our conveyor systems to provide a handoff to inline flipping devices, which may be a customized station or a robot arm.

MD: How do you see the evolution of conveyance systems affecting workflow efficiency in manufacturing?

JA: Not only is throughput able to be increased, but users are also seeing a better total cost of ownership evaluation. High-speed smart conveyance systems allow building footprints to be smaller and add flexibility to the workflow process, thus producing more goods in a smaller area in a shorter timeframe.

BL: We are seeing continued requests for faster systems that allow for heavier payloads. With these faster and heavier loads, work can be processed at very high rates, but these systems are usually guarded against operator intrusion. Where operator processes are required, these same systems can be slowed to a safe speed.

MD: What advancement in materials science are influencing the design of conveyance systems for robotics?

JA: Linear motion and magnetic propulsion are leading this design change. Improvements in material efficiency allow for greater control and speed.

BL: Conveyor systems have not changed in many years, which is a testament to the design and materials used. The main advancement in conveyance is the move from standard induction motors and gears to linear motors. These linear motor conveyor systems require additional design work to allow for the increased speeds and functionality.

Design software is helping manufacturers have a more hands-on approach to developing customized solutions, while also reducing the speed to market and installation.

MD: How do you see artificial intelligence playing a role in future conveyance designs?

JA: AI will initially produce theory models on how controls and automation can theoretically be improved. There will still need to be validation of these concepts until more data points are added. Eventually, with enough data for the AI model, the concept of conveyance designs to match product assembly could, in theory, be simplified.

BL: It’s unknown how artificial intelligence will play a role in conveyor design, but we are seeing increased requests for full-system simulations. This may lend itself to using AI to help determine where bottlenecks exist in current layouts and may provide options for improvement.

MD: In light of increasing automation, what unique challenges do you anticipate for future conveyance systems?

JA: Speed with the ability to work within human interactions will be the greatest challenge. Some tasks still require that human element and safter of those operations is paramount.

BL: We are seeing the requirement for complete system startup in a much shorter timeframe than previous years. The companies who can provide a functional system to an end user with the shortest lead-time seems to win this business over more traditional delivery schedules.

MD: What emerging technologies do you think will have the biggest impact on the functionality and design of conveyance systems in robotics?

JA: Smart conveyance systems are becoming more building blocks every day. This will continue to simplify the assembly concept and allow interaction between conveyance and robotics to be the norm instead of the new thing to try and implement.

BL: As mentioned earlier, linear motor-based conveyors with increased speeds and load capability will have a big impact on traditional conveyance opportunities. In addition, we are seeing an increase in the use of Automated Guided Vehicles (AGVs) along with Autonomous Mobile Robot (AMRs) as a complement to traditional conveyance systems.

MD: How can engineers ensure their conveyance designs adhere to best practices in safety and ergonomics?

JA: Safety and ergonomic standards are pretty set in that all current and future designs will need to adhere to. Nothing changes here regardless of the type of conveyance.

BL: During the design phase of conveyor systems, there are standard guidelines used for ergonomic and safety requirements. These include the median presentation height, speed and potential “pinch points” that may be present. Most companies have these requirements in place prior to starting a new design.

MD: Is there anything else that our audience of mechanical and design engineers in industrial manufacturing should know about conveyance systems as they are used with robotics and automation?

BL: Product knowledge, flexibility and an “outside of the box” approach is needed to design new systems. Teaming up with a partner who has worked with many different applications and who is familiar with the latest technologies will lead to success.