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AUTOMATED ROBOTIC ASSEMBLY LINE “ARAL”
AUTOMATED ROBOTIC ASSEMBLY LINE
“ARAL”
CURRENT TECHNOLOGY2
THE IDEA3
PROCESS TECHNOLOGY4
Content
THE INSPIRATION
ARAL
1
5
FINANCIALS6
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THE INSPIRATION
THE INSPIRATION BEHIND THE IDEA
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CURRENT TECHNOLOGY
THE IDEA – BASIC PANEL ASSEMBLY PROCESS
THE IDEA – CONSTANTLY MOVING ASSEMBLY LINE
THE IDEA - CURRENT TECHNOLOGY USING A MOTORISED CONVEYOR
THE IDEA - CURRENT TECHNOLOGY MANUAL
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THE IDEA
THE IDEA - AUTOMATION USING ROBOTICS TO FAÇADE PANEL ASSEMBLY
THE IDEA - FIRST CONCEPT – AUTOMATION SINGLE PLACEMENT
THE IDEA - FIRST CONCEPT 3D ILLUSTRATION
3D IMAGE
• Carry out manufacturing tasks faster, more consistently, more cost-effectively and with higher quality than manual labour.
• Robots perform tasks exactly as they are programmed to.
• Robots carry out tasks with an extremely high degree of repeatability, with every parameter in the process
automatically monitored and verified.
THE IDEA – WHY USE ROBOTIC AUTOMATION?
BECAUSE ROBOTS……
THE RESEARCH – WHAT WAS THE RESEARCH
The research was an exploratory, quantitative, single-case study that
examined current and improved production methods within a leading
curtain wall manufacturing company. It explored the concept of an
Automated Robotic Assembly Line (ARAL) and made comparisons in
performance to current manual assembly methods.
THE RESEARCH – ON THE INTERNET AND WITH ROBOTICS COMPANIES
Research on robotic integration is narrow, focusing primarily on the application on job sites.
Another study simple single cell application of silicone.
There is a book titled ‘Robotic Fabrication in Architecture’ presents fabrication techniques using wood in architecture
THE RESEARCH - CONCLUSION
BUT…….There is an apparent lack of research related to automation within the curtain wall industry, specifically for automated pre-fabricated building envelope construction.
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PROCESS TECHNOLOGY
CURRENT PROCESS TECHNOLOGY
Advances in process technology and the current state of robotics and automation show that robotic technologies, provide the ideal platform to merge concepts and theories to harmonise the approach and degree of automation.
Developing production innovation, operations and process management activities within the curtain wall industry blending what we know today about how to manage these activities, with what we want to do in the future concerning the level of automation, is the focus of this research.
PLACING THE PANEL ASSEMBLY ON THE V-V MATRIX
The activities in the curtain wall manufacturing plant are inherently repetitive and mostly predictable. Thus, the curtain wall production is classified as a mass production item and positioned accordingly on the volume-variety matrix
PLACING THE PANEL ASSEMBLY ON THE V-V MATRIX
Fig. 5 shows current technology, a conveyor, usually continuously running that links all stations. All processes are manual, other than the moving conveyor, the glass lifting unit and silicone application machine. Line flexibility is a positive point to this process and assembly line workers can quickly adapt to changing panel configurations.
4 MAIN ACTIVITIES
COMPARISONS OF FOUR FACTORIES
COMPARISON SUMMARY
Time / MinsNo. of men Total mins M.h
Frame assembly 20 2 40 0.67
30 6 180 3.00
Factory #3
seconds 517 9 10 86.17 1.44
seconds 664 11 10 110.67 1.84
total average times 17 104.21 1.74
Time / MinsNo. of men Total mins M.h
Fixing backpan assembly 20 2 40 0.67
20 4 80 1.33
Factory #3
0 0 0.00 0.00
seconds 1432 24 16 381.87 6.36
total average times 16 125.47 2.09
Time / MinsNo. of men Total mins M.h
Installation of glass 20 6 120 2.00
25 3 75 1.25
Factory #3
seconds 372 6 14 86.80 1.45
seconds 925 15 16 246.67 4.11
total average times 17 132.12 2.20
Time / MinsNo. of men Total mins M.h
Application of silicone 20 2 40 0.67
25 2 50 0.83
Factory #3
seconds 540 12 14 168.00 2.80
seconds 925 15 16 246.67 4.11
total average times 18 126.17 2.10
Factory #1
Factory #2
Description
DescriptionFactory #1
Factory #2
Factory #4
Factory #4
Factory #2
Factory #4
DescriptionFactory #1
Factory #2
Factory #4
DescriptionFactory #1
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AUTOMATED ROBOTIC ASSEMBLY LINE (ARAL)
THE RESEARCH – THE IMPROVEMENT
The ultimate objective for all operations and process management activities is:
Improvement.
Improvement is the action of closing the gap between the current and the desired performance of an action or process
THE FINDINGS – SIMULATIONS SOFTWARE TOOLS
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THE FINDINGS – USING CURRENT HIGH TECH SOFTWARE
For CNC programming there are 3 basic steps.
1. 3d Modelling2. Tools assignment3. Position of vice grips...etc.
Inventor drawing is converted to a step file in Autodesk
Imports to CAMPLUS, runs analyser for holes and does virtual matching
Imports file to Satellite
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THE FINDINGS – MACHINING PROCESS USING CAMPLUS
THE FINDINGS – THE IMPROVEMENT (CONCEPT 1)
THE FINDINGS – THE IMPROVEMENT
Driven through CAD/CAM Software
or"Teaching" mode
orStep-by-Step programming
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THE FINDINGS – SOFTWARE….STEP……ROBOT
THE FINDINGS – THE IMPROVEMENT
Activity Time/mins ROBOT Time/mins MANUAL
Frame Assembly Parts Load 2
Silicone application to ends 2
Screw feed/torque tool 2 20
total 6 mins 20 mins
THE FINDINGS – THE IMPROVEMENT
THE FINDINGS – THE IMPROVEMENT
THE RESEARCH – STRENGTH AND WEAKNESS COMPARISON
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Meinhardt
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PART 5: THE FINANCIALS
THE RESEARCH – LABOUR COST
0
5000000
10000000
15000000
20000000
1 2 3 4 5
MANUAL VS ROBOTICSeries1 Series2
THE FINDINGS – LABOUR COST REDUCTION
THE FINDINGS – EARNING POTENTIAL
THE FINDINGS – PAYBACK PERIOD
A FINAL WORD….
What will it take for us to break out of the cycle of making things by hand?
This is a challenge we need to solve in our generation
I have presented compelling facts that show robotics is…..
The way of the future…….!
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