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Case Studies

De-Burring System

iA-ROBOTICS is reshaping the industry by changing the way aluminum wheel makers manufacture their products. Wheel manufacturers were faced with high overhead and labor costs, employee job dissatisfaction and injuries, and product quality issues encountered during the manual material removal process. Due to variations in the cast wheels, the material removal feature also had to be positioned within 0.020mm.

We used an industry “first-of-its-kind” approach to hold the 0.020mm positioning accuracy. To accomplish this, we sourced an EOAT from ATI, developed a 3-axis table with high iRVision to locate the material removal feature, and developed a complex algorithm to make the iRVision talk to the 3-axis table and the FANUC LR-Mate 200iD robot. Because of this, we were able to find unnecessary components and reduce the size of the system, simplify the process, and improve the overall safety of the system. This production system is setup to run 20 different part styles; however, it can be setup to run 50 part styles and more with memory upgrades. The project was also completed under budget.

This allowed us to fully automate the process and alleviate manufacturing issues with no special operating skills. By implementing automation in place of manual material removal, manufacturers were able to double production by running 24/7 without regard to lighting/heating, confined spaces, or overtime. Improved production resulted in consistent high quality, faster and more efficient work, less inventory, less scrap, greater yield, and greater flexibility in product design and meeting customer demands. Employees enjoyed better working conditions and greater opportunities for re-tasking with no boring or repetitive tasks.

These factors ultimately led to a significant increase in end-user profits and success by increasing quality production, lowering costs, and eliminating associated Workers' Compensation claims. Future plans include applying similar technology in the aerospace and furniture manufacturing industries to gain significant market advantage.

 

Drill & 3D Scan System

Customers were experiencing challenges when drilling 15 ft. parts that were very difficult to work with. Prior to automation, processing time was around 10 weeks and 80% of the drilled parts did not pass quality control systems. Customers were frustrated with long processing times, variations in quality with costly high volumes of scrap, and high employee turnover and difficulty finding skilled replacement talent.

iA-ROBOTICS developed a "Robot on Rail" system approach, using a FANUC R-2000iC/165F robot, to reach all drill and inspection requirements to solve these issues. Along with the system, we developed a complex algorithm to allow the drill, 3D Scanner, and rail to communicate. The 3D scanner locates the site(s) where the holes were last drilled and returns to the same location to continue, even when the part has been turned. The tiny holes are precision-drilled resulting in extremely high quality close to 100%. Because of this, we were able to resolve quality control, operating cost, and talent issues. This project was also completed under budget.

These factors ultimately led to a significant increase in end-user profits and success by increasing quality production, lowering time and costs, and eliminating associated Workers' Compensation claims.

Fastener Load | Unload Robotic System

Aerospace manufacturers were frustrated with low productivity, operator injuries, high turn-over rates, and high compensation rates for simple repetitive tasks. Operators allowed machines to idle or run slowly to avoid having to work hard, or they simply didn’t show up for work at all. Employees were injured by handling parts manually. Poor quality parts were rejected by end-users due to lack of inspection. These issues led to product quality issues, high overhead and labor costs, employee job dissatisfaction, and injuries resulting in increased Worker’s Comp claims.

iA-ROBOTICS introduced our LR Mate 200iD/7L robotic system with inspection capabilities to solve these issues. Using this system, the operator only loads the part trays, then moves on to other tasks for the remainder of the shift. The robot takes over this entire production sequence by picking parts from the trays and loading|unloading the CNC machine. The robot starts the machine and monitors errors, while inspecting the parts. If over- or under-size parts are detected, the robot tells the machine to offset the cut, then places the resulting good parts back in the tray or bad parts in the reject bin.

Automation advantages vs. manual operation includes smaller footprints, and constant and consistent multi-task productivity with minimal operator intervention. Automation also improves production rates and quality, and operators enjoy better working conditions and greater opportunities for re-tasking without boring repetitive tasks or chance of injury.

These factors ultimately lead to a significant increase in end-user profits and success by increasing quality production, lowering costs, and eliminating associated Workers' Compensation claims. Services provided include robot programming, system integration, and preventive maintenance. Project completion is currently running less than the scheduled 12 week time frame and is under budget by 30%!

 

Furniture Assembly System

Customers were facing lengthy process times and production quality issues, and the difficulties encountered when working with bulky complex parts. They were further frustrated with high overhead and labor costs, and employee job dissatisfaction and injuries.

iA-ROBOTICS' approach consisted of adding two FANUC M-10iA10M robots to assemble the furniture. We also developed a complex algorithm to allow the robot to handle part, use iRVision to locate the correct assembly position, and screw in bolts to parts within torque specifications. This allowed us to fully automate the process and alleviate manufacturing issues with no special operating skills. 

By implementing automation in place of manual assembly, manufacturers were able to improve employee satisfaction by eliminating repetitive tasks, increase production, and improve quality, while lowering operating costs and Workers' Compensation claims. This project is still expected to be completed under budget.

These factors ultimately led to a significant increase in end-user profits, success, and garnered respect from peers and the industry. This technology may also have other applications in different industries.

Educational Training Cart

Education professionals were looking for answers to provide work readiness technology training to students prior to entering the workforce. They were previously unaware of the existence of our training cart and tri-pronged training course approach.

We developed iA-INSTRUCTS to achieve this goal as applied to the robotics industry, and to familiarize students with our brand. This comprehensive program features a fully equipped training system and cart, including a FANUC LR-Mate 200iD/4S, iRVision system, pneumatic grippers, and proximity sensors. A complex algorithm was also developed to simplify the training process, which was easy to understand and user-friendly.

Education professionals are thrilled with results of the iA-INSTRUCTS program and how it will help them achieve their goals. Students will gain hands-on classroom instruction that will lead to workforce readiness immediately upon graduation. Manufacturers will reap the benefits of having a greater number of fully trained students prepared to enter the workforce.