Visions for the future – a question of perception
Survival of the fittest – only those companies willing to innovate and think outside the square will come through the crisis unscathed.
While the financial crisis threatens economies worldwide, contrary to popular belief, it’s not all doom and gloom for Australian manufacturing. In fact, as Katherine Crichton discovers, it could be more the opposite.
AS this article goes to print, one of the most financially turbulent and uncertain years in recent history has just ended with, according to some, no respite in sight for 2009.
While the media has been having a field day with routine announcements of job cuts, record lows for manufacturing activity and the global economy on the brink of recession, believe it or not, currently for manufacturers in Australia, things are not as bad as they seem.
Clyde Campbell, CEO, Machinery Automation & Robotics, believes while there is obviously a lot of uncertainty in the business economy in general, there is also a positive market for people out there who want to take advantage of it.
“Australia’s economy is performing a lot better compared to other countries and very few are predicting that we will go into a recession in 2009. There are still some growing markets in Australia,” Campbell said.
Paul Gekas, MD, ABB Australia is equally optimistic about the future of Australian manufacturing, but says a concern for Australian manufactures is the slow adoption of technologies which could help them in a rapidly changing marketplace.
“Investing in these technologies does require people to be prepared to take that leap of faith into less conventional systems. For many it is a different way of thinking.
“If we look at countries like Europe where the cost of labour is quite high combined with stringent quality standards, the use of industrial robots in non-traditional robotic automation areas is quite high,” Gekas pointed told Manufacturers’ Monthly.
“In Australia, the technology seems to be limited to automotive manufacturers or large food producers.” While many seems to be taking a ‘wait and see’ approach, Campbell and Gekas believe there are definitely opportunities for manufacturers in Australia during the current global economic situation.
“With a reduced Australian dollar placing many Australian manufacturers in a more competitive position globally, and an increased impetus to manufacturer at home due to high import costs, many companies are not only looking to be leaner to consolidate costs, but with changing market conditions, flexibility is key to the success for many companies,” Campbell said.
Gekas also stresses the importance of flexible solutions for manufacturers who need to adapt processes more quickly than they can with traditional manufacturing systems.
“Everyone is looking for flexible systems that can very quickly bring on new lines and new models.
“This drive for flexibility is putting robots into areas where perhaps there may have been a materials handling, conveyor or transfer systems used.
“Now robots can be used in these processes as they are much more quickly configured and hence the structural integrity of the line can be maintained. Just by changing components and re-programming the robot, you can be producing a new vehicle very quickly.”
Some of these robotic solutions providing manufacturers with flexible and innovative options include innovative developments in touch and vision systems.
Eye on vision
One of the most important challenges facing developers of robotic-based vision systems is depth perception or the ability to judge an object’s distance from a camera system. Many systems use stereo cameras to provide depth information to a host computer. In turn, this information is used by robotic systems to locate objects in 3-D space.
Campbell explained to Manufacturers’ Monthly there are several ways depth perception can be achieved.
“Time-of-flight (TOF) cameras can be used to provide depth data of real world scenes at video frame rates. They do this by calculating the actual distance in each pixel giving a third dimension.
“Other ways to attain depth perception is by laser striping or using a laser line of scanners which gives depth across each pixel and can be accurate to less than 1mm.”
“These kinds of solutions/technologies are available now. But is something that not every application requires, so that is why we only provide the technology the solution requires.
Traditionally, three-dimensional vision has involved multiple cameras or a laser rangefinder, but both approaches have drawbacks. The first doubles the number of cameras needed, while the second requires a rapidly moving beam.
Improvements in the technology though, we can do depth in multiple ways, with integrators developing a single camera single, eliminating excess consumables and easier to calibrate.
Can be used in many applications, from food – robotically cutting red meet, calculating how deep to cut, grinding down a certain distance.
Used with most industries, grinding down parts. Heavy industry, grind down to a part with a known depth. Are these notes?
The right touch
Advances in computing and sensor systems capabilities are also driving developments in robot touch systems, which have potential benefits for a range of manufacturing applications.
With new developments in software and high performance controllers, the technology now exists to give robots tactile sense, enabling the machines to interact with objects and manipulate them.
Gekas says one of the main advantages of new ‘touch’ software such as the company’s Force Control which is designed to be used in machining applications in which the robot needs to be sensitive to process forces, is the elimination of existing issues.
“The traditional way in which a user programs a robot is to define the path and the speed. These will be constant, independent of the process forces. If the path does not coincide with the surface and dimensions of the part, you will instantly have quality problems and potential damage to the tooling.
He explained makes the robot possess the capability of quickly and accurately adapting machining to the surface contour and consistency of the materials and component parts to be processed.
“Sensors can detect a situation and the software in the robot controllers will identify it and correct the robot path/speed almost instantly.”
The software incorporates three main features: FC Graphical Programming Interface; FC Pressure which lets robots grind, polish, or buff castings while maintaining a constant pressure between the tool and the work surface, while FC SpeedChange, enables a robot to debur or deflash part line and surfaces of castings at a controlled speed and slowing down when encountering excessive burr.
“These features all add a new dimension to the use of robots in machining operations, that will result in improved process results and product quality, higher productivity, reduced programming time, shorter cycle time and lower cost,” he said.
Article from Manufacturers Monthly - February 2009 Edition
Machinery Automation & Robotics
1/101 Derby Street
Silverwater NSW 2128
Phone: (61) 2 9748 7001
http://www.machineryautomation.com.au