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 Technical Focus: Using Robotics in Automated Pad Printing     Above: simple three-axis "pick-and-place" robot application for unloading finished parts into bins. Note the purple arrow in each frame indicating the movement of the "hand". Robotics Features:  Flexibility Speed Accuracy Performs Repetitive Tasks Without Negative Boredom Factor Self-Diagnostics Ability To Re-Purpose Unit for Other Applications Robotics Benefits: Minimal Downtime Maximum Repeatability Maximum Productivity Interfaces with Systems & Components Minimizes Scrap Parts When Integrated with Vision Inspection Enables Exact Positioning of Parts and/or Image When Integrated with Vision- Guided Sensors TYPES OF ROBOTS: • Six-Axis: This most agile and flexible robot unit is capable of performing tasks far beyond the human hand-wrist-arm combination of grasp, turn, reach and so on-- plus with incredible speed. When combined with vision-guidance and almost limitless progamming possibilities, it becomes an extremely smart operator. • SCARA: Selective Compliant Assembly Robot Arm (SCARA) is a category of robots that is similar to the human arm in its ability to grasp an object, lift it to a certain height, reach out to within a certain radius, and place that object at a specific location within its reach. SCARAs are relatively easy to program and feature quick action and accuracy. • Cartesian: These elegantly simple robots are sometimes called "pick & place" units. They come in 1, 2, 3 and 4-axis models; preferred for basic part load & unload functions. Background: In the past ten years, robots have become much more affordable and easy to program. Hence their use has become more widespread and the applications more diverse and creative. The older units were slower and required much more intensive and specialized programming language. Future: As in the personal computer environment, current robot units are much faster, hold much more memory, are easier to program, and are remarkably fast. Future developments may include longer arm reach, standard vision guidance, stronger load capaciry and, if possible even higher velocity. Other Pad Printing Applications Recently, successful applications have also used vision-guided robots that actually perform the function of the pad printer. When the "hand" is fitted with a silcone rubber pad, it is transformed from merely a conveying device to a transfer pad printng machine. Plus, it is now an intelligent or "smart" pad printer.This means the print location is determined by the robot's vision system and then using the pad, prints the part in exact position. This technology is far superior to post-print vision inspection where an image is placed on the product and then verified optically. By programming the robot to both "find" the target and transfer the image to one or more locations, the process increases both speed and accuracy. The potential applications to product decorating are limitless. More Pad Printing Applications: • food canister • multicolor golfball • satellite dish • toothbrush • catheter luerlock • various catheters • slidemount • syringe • blender housing • medical device • others Contact Us  |
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Fully Automated Product Decorating:
Robotics Extend Reach of Smart Pad Printing Systems
In this automated system, a six-axis robot functions much like an operator by loading, turning, unloading and advancing an acrylic mug to receive multicolor images from a series of pad printers: MKM-80.3, Gemini 60 / 90, and Orion 130 with shuttle. The entire system is surrounded by safety guarding and light curtain.
ONE bit of advice often quoted by many production managers
and consultants goes,"Don't work harder; work smarter." But with operators and supervisors wearing multiple hats and stretching their productivity to the limit, just how much smarter can anyone work before collapsing from exhaustion? Enter the ultimate operator: a robot.
This is what machines were invented for.
An automated pad printing system, though complicated, can be broken down into several individual tasks, most of which can be performed by mechanical or electronic devices. But when an action or decision needs to be made by an operator before the process can continue, that point can become the bottleneck of the production flow-- especially if the action is repetitious. After thousands or even milions of cycles, the "boredom factor" begins to affect even the sharpest or most alert operator. Mistakes happen. Errors occur. Fatigue sets in.
Features and benefits of robotics
Here are a few of the important features that a robotic device can offer to your operation:
• Flexibility
Almost limitless choices of configurations, sizes and applications are available; all programmable and customizable to fit your particular needs-- especially when integrated with systems and components.
• Speed
The remarkable quickness of movement will dramatically reduce cycle time.
• Accuracy
By using servo-controlled components, the tolerance for error is reduced to near zero. This also minimizes scrap parts when interfaced to vision inspection devices.
• Repetitive Consistency Without Human Error
The robot performs repetitive tasks without the negative boredom factor. The results are minimal downtime and minimal errors. The net gain is maximum repeatability and maximum productivity. Plus, no sick days, coffee breaks, or lost personal business time.
• Self-Diagnostics
Most systems include self-diagnostics, batch counting and performance history for documentation and test verification.
• Ability To Re-Purpose Unit
Most robotic devices are modular and therefore can be re-purposed for other applications. Ease of programming enables re-writing of commands and cycle sequences. Also, when integrated with vision-guided sensors, robotic units are capable of exact positioning of parts and/or images in other decorating functions.
At the next printing station within the system, the six-axis robot secures mug in holding fixture while receiving images from Gemini 60 / 90 pad printer. In a typically manual operation, this function would be done by the operator placing part in fixture, then removing hand from print area during machine print cycle.
The fully automated system shown above is comprised of: twelve-position dial, Sealcup 60 pad printer with tape-off, and infra-red spot-cure. SCARA robot functions include: precise picking of part from bulk tray, vision inspection (red light), loading of blank part into fixture on dial, unloading of printed part from fixture, and placing it back into bulk tray. Note the "overflow" rack for parts printed but waiting for open space during tray change. Below: different angle view of same system, showing bulk part tray, SCARA robot with dial in rear. Note the bulk magazine at left for holding stacked part trays ready to be advanced into the fully guarded load-and-unload area.
Overview of another fully automated system with six-axis robot (shown at lower right) incorporates bulk feeder bowl, infeed track, two-up fixtures, eight-position dial, Sealcup 90 pad printer, infra-red curing unit, and vision inspection station. Once inspected, each part is verified as good or bad; then robot either drops it into reject bin or places it in precise location in finished bulk tray. Trays are then advanced along belt to off-load bulk tray rack. Shown below is detail view of robot as it drops rejected part into bin.
Another example of semi-automated pad printing system using six-axis robot (shown above at lower center) to unload parts. This particular system included: sixteen-position Weiss ring, corona pre-treatment, four Comet 130 pad printers, special adjustable fixtures, and auxiliary heat-curing tunnel. Below: detail view of six-axis robot unloading printed parts onto heat-curing tunnel belt. The robot's ability to adjust its hand to various part widths and shapes, as well as its speed and agility in picking and placing parts were valuable features.
To discuss how using a robot in your pad printing application may be part of a custom-engineered, automated system, feel free to contact your local ITW Trans Tech rep at: www.itwtranstech.com
ITW TRANS TECH • An Illinois Tool Works Company
475 North Gary Avenue • Carol Stream, IL 60188-4900
Phone: 630.752.4000 • Fax: 630.752.4460
www.itwtranstech.com
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