Investigating the basics of six-axis robots, how they are structured, the key components, advantages and applications in the industrial sector


What is a Six Axis Robot: Exploring the Versatile Powerhouse of Industrial Automation

Automotive robots are reshaping production processes, enhancing quality, and redefining the future of the automotive industry. Let’s discover how these mechanical marvels are driving innovation on factory floors worldwide.

Automotive Robots: Revolutionizing the Assembly Line

A pick and place robot in an industrial setup

Understanding the inception, evolution, composition, and types of pick and place robots and their impact on various industrial sectors 

Pick and Place Robots: An In-Depth Guide to Their Functionality and Applications

DFKI will be presenting its strawberry-picking robot to the public for the first time in&nbsp;Hall 23a. A row of strawberry plants has been specially planted for the smart robot at the joint stand of the Kuratorium für Technik und Bauwesen in der Landwirtschaft e.V. (Board of Trustees for Technology and Construction in Agriculture). It is designed to be small, flexible and inexpensive, and to harvest fruit independently. The system is being developed as part of the RoLand (Robotic Systems in Agriculture) project, coordinated by the Robotics Innovation Centre (RIC) at DFKI Bremen.&nbsp; &nbsp; The concrete application scenario is strawberry harvesting in the open field, which poses an increasing challenge for fruit growers. Agricultural businesses, such as the Glantz strawberry farm associated with the project, are complaining about a decline in seasonal labour on the one hand and rising wages on the other, says DFKI project manager Dipl.-Ing. Heiner Peters: "This is where our robot comes in. It is designed to support and relieve the labourers during the harvest. If necessary, it can work in parallel or even be used at night." The system enables cost-effective automation in agriculture. The use of several robots is conceivable on larger fields.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1705298738122-1705298738122.png" style="width: 766px;" class="fr-fic fr-dib">The animations show how the strawberry picking robot should work in the end. Two arms pick a strawberry every three seconds. Animation: DFKI, Meltem Fischer<h3>AI recognises ripe fruit</h3>The technical components of the strawberry picking robot are a mobile platform, a fruit recognition system and a harvesting gripper. With the help of artificial intelligence (AI), the robot recognises which fruits are ripe enough to be picked. This AI method can potentially also be transferred to other types of fruit.The system will initially be on display at the Grüne Woche with just one gripper arm, with grippers on both sides planned for the long term. One of the challenges for the researchers is to enable the gripper arms to cleanly separate ripe strawberries from the stem without crushing them. These problems are currently being addressed in the project. Peters: "Our aim is to pick a strawberry with each gripper in six seconds by the end of the project, meaning one every three seconds in total. That is roughly equivalent to the picking performance of a human."RoLand is being funded by the Federal Ministry of Food and Agriculture with a total of 1.7 million euros over a period of three years (1.10.21 - 30.9.24). The Robotics Innovation Centre at DFKI is coordinating the project. The project partners are the Research and Transfer Centre (FTZ) of the Hamburg University of Applied Sciences (HAW), Othmerding Maschinenbau GmbH &amp; Co. KG and Glantz Erdbeerhof (associated).<hr>Further information:<a href="https://robotik.dfki-bremen.de/en/research/projects/roland" target="_blank" rel="noreferrer">https://robotik.dfki-bremen.de/en/research/projects/roland</a>Venue: Hall 23a, special exhibition hall of the BMEL - Robots in AgricultureBooth: Kuratorium für Technik und Bauwesen in der Landwirtschaft e.V. (KTBL)

The strawberry-picking robot that DFKI is currently developing and is now presenting to the public for the first time is designed to be small, flexible and inexpensive. 

The German Research Center for Artificial Intelligence will be presenting new technologies for agriculture in three exhibit halls at the International Grüne Woche, which will take place in Berlin from 19 to 28 January 2024.

DFKI presents strawberry picking robot and AI ecosystem

The work in the greenhouse at Beerstecher AG in Hinwil is demanding. With humidity levels of 80 percent and temperatures of up to 35 degrees Celsius, those working in it very soon find themselves exhausted. The family business in Hinwil is consequently faced with a challenge when finding and retaining suitable labour for its vegetable harvests.<iframe width="640" height="360" src="https://www.youtube.com/embed/M_W38gdWgiI?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>Video: ETH Zurich / Nicole DavidsonThe picking robot from ETH spin-off Floating Robotics addresses these challenges. It automates crucial tasks such as defoliating, harvesting and boxing vegetables. “The robot primarily takes over strenuous and repetitive activities, allowing our employees to focus on more demanding tasks that require a creative and critical mindset," explains Bianca Curcio, who is responsible for production management in the Beerstecher greenhouse and is an ETH Zurich alumna.Although the robot is still in the pilot phase, Curcio anticipates it will play a permanent role in Beerstecher AG’s production process.The robot was developed by engineers and students from the Robotic Systems Lab (RSL) at ETH Zurich. Under the leadership of Salman Faraji, they established the spin-off Floating Robotics in 2023 with the aim of bringing the technology behind the picking robot to the market.Equipped with an integrated camera, the robot monitors the crops, and with the assistance of its built-in computer can recognise different plants and objects. Its robotic arm is activated to perform specific tasks, such as de-leafing or harvesting.

Working in a greenhouse is both strenuous and time-​consuming. The picking robot from ETH spin-​off Floating Robotics takes on particularly repetitive tasks, thereby alleviating the strain on human pickers. It is currently undergoing testing at Beerstecher AG in Hinwil.

A picking robot for the greenhouse

In a warehouse or production facility, packing refers to the process of preparing goods and products for shipment or storage by placing them into appropriate containers or packaging materials. Packing presents many challenges that can significantly impact operational efficiency and overall productivity. One primary concern is the traditional toll it takes on the human-labor force. The labor-intensive nature of packing tasks can lead to workforce fatigue and decreased morale, potentially affecting safety and productivity.This article explores the need and benefits of automated packing solutions to streamline warehouses and production facilities, reduce time to delivery and increase safety. It highlights the features and applications of BRIXX&reg;, a new automated packaging solution with modular components and click-and-play-based software.<h1>Challenges in Packaging</h1>To understand the challenges in packing, it&rsquo;s crucial to understand the stages of packaging and packing along the &lsquo;product to pallet&rsquo; line. A product packaged in its for-consumption form is known as its primary packaging. Secondary packaging is used to group a certain number of products to create a stock-keeping unit, commonly referred to as a SKU. This helps the handling of smaller products and also adds a layer of protection for them during transport. Tertiary, bulk, or transit packaging is used to group larger quantities of SKUs to transport them from point A to point B (e.g. from the production facility to the point of sale). An example of tertiary packaging is a stretch-wrapped pallet containing a number of cardboard boxes (secondary packaging) to enable efficient product shipping.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgzMTgxOTgyNjU5LTEgZmxleC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib">A warehouse with a manual packing process.The challenges in automating packing lie at the secondary and tertiary stages because the conventional method of manual packing is costly and time-consuming due to the need for a large amount of labor. Complex packing requirements such as multiple product types and fragile items increase this labor need. This can then be further increased by seasonal demand.&nbsp;<h1 id="isPasted">BRIXX&reg;: An Innovative Packing Solution</h1>An example of an innovative solution for packing automation is BRIXX&reg;, a solution from <a href="https://www.flexlink.com/en" target="_blank">FlexLink</a>, a Coesia company. BRIXX&reg; is a modular, click-and-play software-based solution that reduces manual operations and provides an easy way to customize the process in co-packing lines. The solution was launched at <a href="https://www.interpack.com/vis/v1/en/exhprofiles/rOVtwM2eQ46OgVnf1sGOVw?oid=55128&lang=2&_query=flexlink" rel="noopener noreferrer" target="_blank">Interpack 2023</a> and can be seen live until 10 May.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgzMTgyMDM0MTM1LTIzMDMwMl9CUklYWF9wcm9kdWN0aW9saW5lX0xpZ2h0R3JleV9CYWNrZ3JvdW5kLTMwMDB4MjEyMS01ODliZDMxLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib">Mixing of products with BRIXX&reg; modules Image credit: FlexLink.With BRIXX&reg;, companies can automate operations for various products, including packages, cartons, and trays. The flexible system provided by Flexlink is scalable to meet varying production needs while remaining affordable and user-friendly. This is possible through advanced mobile conveyor modules and the use of robots to automate repetitive manual packing and co-packing processes.<h3>Modular approach to packing</h3>The BRIXX&reg; system comprises conveyor and robot modules that work with an intuitive software overlay. The modules are easy to move, connect, and power and can be configured in various ways to suit the packing needs of thier location. They are also equipped with visual indicators for operational status, a built-in vision system, and automatic calibration. The modules use the same power connection, simplifying their setup and maintenance.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgzMTgyMDc5MjU3LWZsZXgyLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib">The&nbsp;BRIXX&reg; units can be configured in various ways to handle diverse packing tasks.&nbsp;&nbsp;Packing facilities can leverage the modularity and ease of set-up of BRIXX&reg; to become a hyper-agile packing line. A facility may set up one configuration of BRIXX&reg; for one packing task, such as palletizing, and then quickly reconfigure to enable them to complete a different type of task, such as labeling. This modular &lsquo;super power&rsquo; means packing facilities can offer more services to their customers and manage unexpected requests rapidly.The robotic arm module has a moveable, connectable base with a multi-degree robotic arm with a single or multi-pick vacuum gripper. The conveyor belt line is a simple unit with a speed-adjustable conveyor belt that can link to other units to form continuous packing lines.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgzMTgyMTkyNjY5LUZsZXhMaW5rLTIzMDIyMi0xNS0yMDQ4eDEzNjUtMjNmMTY2My5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib">The modules click and connect using the same modular system. Image credit: FlexLink.The flexible combination of BRIXX&reg; modules enables various operations with the same hardware and software. Production companies or co-packers can automate packing actions such as pick-and-place, mixing, labeling, re-labeling, palletizing, or de-palletizing for increased productivity and efficiency. Product transformations, such as case forming, tray forming, and carton closing, are optionally available. <h3>BRIXX&reg; Software&nbsp;</h3>The BRIXX&reg; software is designed to be user-friendly and easy to operate. It has drag-and-drop functionality that enables the rapid setup and adjustment of the system. A functioning automated packing line can be set up with the assistance of step-by-step visual instructions. Additionally, the software provides real-time production monitoring through overall equipment effectiveness (OEE) indicators and alarms. Its human-machine interface also allows you to plan for ordinary and extraordinary maintenance.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgzMTgyMjQ1MTY4LUZsZXhMaW5rLTIzMDIyMi0yOC0yMDQ4eDEzNjUtMjNmMTY2My5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib">The BRIXX&reg; software enables users to design efficient packing lines, check for maintenance, and monitor processes. Image credit: FlexLink.Hence, the user can rearrange the robotic modules and change instructions and configurations in the code according to the hardware setup. The system supports up to 5 different conveyor layouts.The BRIXX&reg; software also features a built-in SKU management system with a selector guide, allowing the user to manage inventory. It also features MES-ERP integration tools thanks and an optional unified name-space MQTT open interface to support inventory management for packaging and labeling units.<iframe id="644a3752133e690008b02766" width="250" class="specs-iframe" height="420" src="https://wevolver.com/iframe/specs/brixx-packaging-automation-system?iframe=true" frameborder="0" scrolling="true" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> The system also allows up to 4 user levels to help set up various permissions and restrictions on controls. It has real-time monitoring features that include alarms and OEE indicators. Moreover, remote assistance packages and an integrated HMI system are helpful for preventative maintenance and planning.The software features PackML standard support backup and restores features in IPC for additional security. Each unit has a dedicated software license and an additional Android application to enhance functionality for packaging line operators.The BRIXX&reg; solution enables companies to quickly adapt to the increasing demand for automation to increase efficiency and lower costs. The system&rsquo;s unique modularity ensures companies can lower thier risk while being prepared for seasonal and consumer changes.&nbsp;<h3>Applications</h3>The BRIXX&reg; system is suitable for many standard packing applications required by warehouses and other packing facilities. Common applications include adding boxes to pallets, known as palletizing, removing boxes from pallets, adding SKUs to other tertiary packaging, and labeling and relabelling.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgzMTgyMzM5OTI2LWFwcGxpZmxleC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"><h1 id="isPasted">Conclusion</h1>Automated packing solutions can increase efficiency and reduce costs and material waste by contributing to reduced packaging time and a company&#39;s sustainable footprint. FlexLink&#39;s BRIXX&reg; solution combines robot modules with intuitive software to automate secondary and tertiary packing applications.&nbsp;<h3>Learn more about BRIXX&reg;</h3>Flexlink is launching the BRIXX&reg;&nbsp; solution during <a href="https://www.interpack.com/vis/v1/en/exhprofiles/rOVtwM2eQ46OgVnf1sGOVw?oid=55128&lang=2&_query=flexlink" rel="noopener noreferrer" target="_blank">Interpak 2023</a>. Visit them at their stand in Hall 6/D31.&nbsp;

An automated packing system leveraging modular components and intuitive software to address labor-intensive challenges, optimize operational efficiency, and streamline product handling processes. 

Modular Automated Packing System Offers New Flexibility and Agility

Partners:<a href="https://tipteh.com/" target="_blank">Tipteh</a><a href="https://www.hella.com/hella-com/index.html" target="_blank">Hella</a>Problem:The customer needed to automate the task of taking plastic parts from one machine where they were being dried and putting them into another machine for further processing and testing. Before, this task was performed manually by workers.Solution:<a href="https://www.photoneo.com/locator-studio/" target="_blank">Locator Studio</a> + <a href="https://www.photoneo.com/phoxi-3d-scanner/" target="_blank">PhoXi 3D Scanner</a>The customer decided on a solution from Photoneo &ndash; the Locator Studio with a PhoXi 3D Scanner.The process looks as follows:The parts arrive on a plate. The robot requests information about the objects&rsquo; location and position. The PhoXi 3D Scanner makes a scan of the scene and the data is immediately processed as a point cloud. This is followed by CAD localization and defining the position and rotation of each object in the form of X, Y, and Z coordinates.After the robot receives an object&rsquo;s location and position, it can proceed to the picking action. It is equipped with a universal gripper that can pick several different parts. Fast localization and picking of multiple objects are enabled by Locator Studio&rsquo;s smart memory and the possibility to use a complicated gripper design.The parts need to be placed into a processing machine with submillimeter accuracy. This is ensured by measuring the part position in the gripper with the 3D localization system and by adjusting the robot arm coordinates accordingly.This type of application does not require path planning with collision avoidance so Photoneo&rsquo;s Locator Studio was a perfect choice.Discussion:The customer decided on this solution because it provides the following advantages:<ul><li>No need for path planning with collision avoidance, which leads to faster picking speed than traditional bin picking solutions</li><li>No need for different grippers to pick various parts</li><li>No need for a separate positioning mechanism prior to picking</li><li>High flexibility &ndash; fast changeover to other parts with different shapes</li><li>Simple &amp; fast 3D picking in collision-free environments&nbsp;</li><li>Fast scanning speed &amp; superior quality of 3D point clouds&nbsp;</li><li>Easy calibration and configuration via the web interface</li><li>Robust CAD-based object localization from a single scan while the robot picks the previous round of parts</li><li>Fast integration with an arbitrary robot system thanks to the TCP/IP protocol</li></ul>The customer was very satisfied with the solution and ordered 4 systems.For more information, <a href="https://www.photoneo.com/contact-us/" rel="noopener noreferrer" target="_blank">contact Photoneo</a>.

Fast localization & picking of multiple objects

Fast localization and picking of multiple objects with Photoneo's Locator Studio for 3D picking in collision-free environments, PhoXi 3D Scanner, and a universal gripper.

Partner:<a href="https://kuzniapolska.com/en/" target="_blank">Kuźnia Polska</a>Problem:Robotization is one of the key areas of investment in modern companies such as Kuźnia Polska &ndash; a company with a 250-year tradition in the steel and metal industry. &nbsp;One of the reasons for the robotization of some tasks was to increase ergonomics and work safety in conditions of high dustiness, very high temperatures, and health hazards. &nbsp;&ldquo;We are eager to robotize those processes where people&rsquo;s safety can be increased and their competence improved by changing their task duties, for example, from operating a press to supervising the operation of a robotized press,&rdquo; says Łukasz Bębenek, Automation Department Manager, Deputy Manager of the Maintenance Department at Kuźnia Polska.&nbsp;&nbsp;Solution:<a href="https://www.photoneo.com/bin-picking-studio" target="_blank">Bin Picking Studio</a> +&nbsp;<a href="https://www.photoneo.com/phoxi-3d-scanner" target="_blank">PhoXi 3D Scanner</a>There are already 7 production cells with industrial robots operating at Kuźnia Polska.&nbsp;Robots from&nbsp;<a href="https://kawasakirobotics.com/" target="_blank">Kawasaki Robotics</a> work at CNC, crank press, and hydraulic press operation stations. &nbsp;&ldquo;Each robotic station is first modeled using 3D software. It allows us to facilitate implementation so that the layout of the station including the production hall, components, and the robots themselves are optimally selected with regard to the reach, lifting capacity, and cycle time,&rdquo; says Sylwia Nikiel, a constructor at Kuźnia Polska. &nbsp;The first robotic station for a milling machine was implemented in 2018, with one type of workpiece to be handled.&nbsp;Here, the workpieces are taken from the storage bin and then placed manually in special drawers. The correctly positioned workpiece is picked up by the robot using a dual mechanical gripper. &nbsp;After the machining process is complete, the robot picks up the final workpiece, inserts a new unmachined workpiece into the milling machine, and moves the finished workpiece to the storage area. &nbsp;In 2021, an intelligent machine operation solution was implemented for a similar machine &ndash; this time with two types of parts placed in two different storage bins. The solution for this bin picking application consists of bin picking software and a 3D vision system from Photoneo &ndash; Bin Picking Studio and PhoXi 3D Scanner &ndash; and an industrial robot from Kawasaki Robotics.This solution allows you to pick workpieces from 2 different storage bins with a different gripper equipped with an electromagnet. The workpieces are scattered randomly in the bins. This eliminates the need for operators to arrange the parts. The storage bins are changed only once per shift.&nbsp; &nbsp;Discussion:The deployed bin picking solution with an innovative 3D vision system is great for applications with high variability of production as it allows fast changeovers and processing of more than one workpiece per station. &nbsp;Advantages of robotization:<ul><li>Increased efficiency&nbsp;</li><li>Ease of use for the operator</li><li>Increased safety for employees</li><li>Proper machine handling of workpieces</li></ul>This type of solution will be useful not only in the metal industry but in any application that involves the picking of randomly scattered parts,&rdquo; says Marcin Brydak, Robotics Consultant at&nbsp;<a href="https://www.astor.com.pl/en.html" target="_blank">ASTOR</a>.&nbsp;Łukasz Bębenek adds, &ldquo;We coordinate the entire implementation by ourselves. Specialists from ASTOR support us at the beginning of the project &ndash; at the R&amp;D stage, selecting robots and renting them for testing, training as well as immediate support if needed. The results? We are able to implement robotic workstations within a very short time. We have decided to work with Kawasaki Robotics because of their high reliability in the demanding conditions of heavy industry&rdquo;.

Photoneo’s robotic intelligence SW Bin Picking Studio and 3D vision PhoXi 3D Scanner are implemented in a robotic bin picking station where a Kawasaki robot picks two types of parts from two different containers and then places them into a machine.

Kuźnia Polska, in cooperation with ASTOR, Kawasaki Robotics CEE Hub, and Photoneo, developed an automation solution for a bin picking application that enables the picking of two types of parts from two different containers.

Bin picking from two different storage containers

Partner:<a href="https://www.kuka.com/en-us/products/robotics-systems/industrial-robots" target="_blank">KUKA</a>Challenge:The customer <a href="http://www.favi.com/en/about-favi/" target="_blank">Favi&nbsp;</a>- a manufacturer and supplier of technical parts for various industries - decided to automate a manufacturing process that involves the picking of parts from containers.The parts manufactured in FAVI&#39;s foundry arrive in bins. These parts must be picked and then placed into a machining center. FAVI needed to develop an application to automate this process. For this, the company has chosen KUKA based on their trusting 15-year-long relationship.Solution:<a href="https://www.photoneo.com/bin-picking-studio/" target="_blank">Bin Picking Studio</a> + <a href="https://www.photoneo.com/phoxi-3d-scanner/" target="_blank">PhoXi 3D Scanner</a>The installed automation system consists of two KUKA KR IONTEC robots, each equipped with a 3D scanner for precise navigation in 3D space.&nbsp;The PhoXi 3D Scanner scans the bin and the Bin Picking Studio detection software determines the position and orientation of the parts inside, calculating the appropriate trajectories for the robot.KUKA has been actively working on simplifying the communication between the 3D scanner and the robot so that the transmission of information is as fluid as possible. This means that the robot can pick up the parts one by one without colliding with one another and take them to the processing machine. A true camera-robot collaboration!Discussion:The major factors that played a role for FAVI in deciding on a solution from Photoneo were the attractive price and easy use of Bin Picking Studio.By automating the task of picking parts from a bin, FAVI managed to remove the physically challenging aspect of the work. Productivity has increased as the factory is running in 2 shifts - now, for the 3rd shift, employees can leave the cell in an autonomous mode, earning some hours of automatic production during the night.The automation solution allows FAVI to optimize its production thanks to the innovative technologies comprising Photoneo&#39;s 3D vision systems and KUKA robots.&nbsp;The two bin picking cells work together and allow FAVI to achieve yield rates of 85%. KUKA provides expertise and support for this bin picking process. The system enabled the strengthening of labor capital since it encourages an increase in the skills of operators, who are now line managers. In addition, automation of the process helps eliminate MSDs (Musculoskeletal Disorders).&nbsp;In 2022, FAVI focuses on a future project with KUKA in order to host a new high-speed uncoiling cell in their warehouses. Xavier Dubreuil, Production Manager at FAVI, says: &quot;The solution is very satisfactory for us, and very well adapted to the types of products we manufacture. The process is linear, reliable, and increases our yield rates.&quot;

This solution for FAVI enables the automation of picking parts from bins using two KUKA robots navigated by 3D vision and robotic intelligence from Photoneo.

Automated bin picking of parts

Partner:<a href="https://imr.ie/" target="_blank"></a><a href="https://imr.ie/" rel="noopener noreferrer" target="_blank">IMR &ndash; Irish Manufacturing Research</a><a href="https://multipix.com/" target="_blank">Multipix Imaging Ltd.</a>Problem:Bin picking of randomly oriented parts is of great interest to manufacturers as automation of these processes can save a lot of costs and space. The market offers a large number of bin picking solutions but many of them struggle with recognizing and identifying transparent, deformable, variable , and reflective objects that may even be piled, entangled, and jumbled up. The Irish Manufacturing Research built a bin picking cell for the picking of 3 different types of randomly oriented bread products.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjQ3NjEwNTEzNjY0LWNyb2lzc2FudHMgKDEpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 765px;" class="fr-fic fr-dib">This project presented several technical challenges:&nbsp;<ul><li>Identification and picking of objects of non-symmetrical and complex shapes</li><li>Random orientation of the objects</li><li>Picking of 3 different types of objects</li><li>Achieving optimal process speed</li></ul>Solution:<a href="https://www.photoneo.com/bin-picking-studio/" target="_blank">Bin Picking Studio</a> + <a href="https://www.photoneo.com/phoxi-3d-scanner/" target="_blank">PhoXi 3D Scanner</a>The solution comprises a bin picking cell with Photoneo robotic intelligence software for bin picking &ndash; the Bin Picking Studio, a PhoXi 3D Scanner, and a UR 5 robot. The supplier of Photoneo technology in the UK is Multipix Imaging.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjQ3NjEwNTg0OTAzLVBpY2tpbmcgb2YgY3JvaXNzYW50cyAoMSkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 765px;" class="fr-fic fr-dib">Before implementation, the following setup and configuration requirements needed to be met: &nbsp;&nbsp;Pre-planning: &nbsp;<ul><li>Defining a suitable end-of-arm tooling design&nbsp;</li><li>Mounting an EOAT gripper and testing its operation on the robot</li><li>Ensuring correct safety requirements (Collaborative mode or Industrial mode)</li><li>Having CAD models (in the STL file format) of:<ul><li>The product to be picked</li><li>The EOAT gripper</li><li>The cell layout&nbsp;</li></ul></li><li>Having the required software files of the UR5 robot for integration with the Bin Picking Studio</li><li>Having the required network cables for a physical connection between Bin Picking Studio, UR5, and PhoXi 3D Scanner</li><li>Having an HDMI cable for connection between Bin Picking Studio hardware and the monitor screen</li></ul>Setup:After all the above requirements had been met, the next implementation steps were:<ul><li>Building the cell and integrating hardware</li><li>Integrating Bin Picking studio hardware and software&nbsp;</li><li>Planning gripper grasping, including all potential grasping orientations and picking points&nbsp;</li><li>Calibration of robot vision and the end-of-arm tooling &nbsp;</li><li>Setting parameters&nbsp;</li><li>Optimization of layout, path planning, and robot parameters&nbsp;</li><li>Repeatability testing &nbsp;</li></ul>The system enables repeatable picking and emptying of random bins filled with 3 different bread products of complex shapes at a picking rate of 6ppm. If the products had a symmetrical shape, the processing speed would be even faster. &nbsp;The system enables an easy changeover between different products.Discussion:This project provides IMR partners and customers insights into the requirements and capabilities of a typical bin picking solution. IMR has invested in a commercial bin picking solution that Irish manufacturers and IMR partners can avail of.&nbsp;The system can be further optimized by:<ul><li>Setting the robot speed to maximum</li><li>Restricting the robot&rsquo;s joint motions for shorter trajectories</li><li>Using smart memory and fast scanning option</li><li>Optimizing localization parameters available in the system</li><li>Using grasp invariance feature that allows multiple possible grasp points on the product</li></ul>

The Irish Manufacturing Research developed an advanced solution for automated picking of bread products, which deploys a UR 5 robot navigated by 3D vision and robotic intelligence SW from Photoneo.

Robotic picking of croissants

Partner:<a href="https://ingenersun.com/" target="_blank">INGENERSUN, S.L.</a>&nbsp;Problem:The customer&nbsp;<a href="https://www.bridgestone.com/" target="_blank">BRIDGESTONE</a> decided to automate the process of tire unloading. The task was performed manually before, which was a tedious job that caused injuries.&nbsp;&nbsp;Solution:<a href="https://www.photoneo.com/bin-picking-studio/" target="_blank">Bin Picking Studio</a> +&nbsp;<a href="https://www.photoneo.com/phoxi-3d-scanner/" target="_blank">PhoXi 3D Scanner XL</a>INGENERSUN, S.L. developed a solution that comprises a robotic cell with a Fanuc M-410iC/315 robot, a 15-meter track, 6 unloading bays, 3D vision hardware PhoXi 3D Scanner XL from Photoneo, software from Bcnvision, and barcode readers for identification. The system also features automatic gripper path rectification for deviated columns.PhoXi 3D Scanner enables the system to recognize the position and height of each column of tires.&nbsp;Discussion:The partner decided on a solution from Photoneo based on the company’s worldwide acclaimed 3D sensing technology and proven best-in-class systems and solutions for vision-guided robotics. Bcnvision collaborates with Photoneo and together they can provide top services for their systems integration in INGENERSUN’s robotic cells.The automation of tire unloading led to the reduction of injuries, increased productivity, and better control of traceability.

INGENERSUN, S.L. developed an advanced solution for automated unloading of tires, which was performed manually before. The solution consists of a FANUC robot, 3D vision and bin picking system from Photoneo, software from Bcnvision, and other components.

Robotic depalletization of tires

Partners:<a href="https://bcnvision.es/en" target="_blank">Bcnvision</a><a href="https://www.ingemov.es/" target="_blank">Ingemov</a>&nbsp;Problem:The customer decided to automate the production process of brake discs to increase productivity and reduce the challenging nature of manually picking the brake discs from a bin.&nbsp;&nbsp;Solution:<a href="https://www.photoneo.com/phoxi-3d-scanner/" target="_blank">PhoXi 3D Scanner XL</a> +&nbsp;<a href="https://www.photoneo.com/bin-picking-studio/" target="_blank">Bin Picking Studio</a>The automation solution deploys a bin picking system that identifies the brake discs located in two bins and sends the coordinates of the part to be picked to the robot.The solution consists of the Photoneo Bin Picking Studio and a PhoXi 3D Scanner.&nbsp;&nbsp;Discussion:The automation solution helped increase productivity and eliminate the ergonomic issues the manual task posed.Bin Picking Studio software is very user-friendly and provides a great bin picking performance, with a cycle time of less than 30 s/piece.

The automation of the production process of brake discs helped increase productivity and reduce the challenging nature of manually picking the brake discs from a bin. 

Bin picking of casting discs

Partner:<a href="https://www.jamk.fi/en/Home/" target="_blank">JAMK University of Applied Sciences</a>&nbsp;Problem:The JAMK University of Applied Sciences provides robotics testing and piloting services, training, and RDI activities for external companies. The companies are interested in testing bin picking and 3D machine vision solutions for their needs. These applications have different kinds of requirements and Photoneo PhoXi 3D Scanner proved to be adaptable and suitable for a wide range of use cases.JAMK students are studying machine vision as part of their automation engineering studies. 3D machine vision is major sensing technology in robotics and with this kind of solutions and systems, the university was able to set up a modern laboratory environment for education in this field.&nbsp;Solution:<a href="https://www.photoneo.com/phoxi-3d-scanner/" target="_blank">PhoXi 3D Scanner M</a> +&nbsp;<a href="https://www.photoneo.com/bin-picking-studio/" target="_blank">Bin Picking Studio</a>One of the applications is an automated process of tiles picking. This task comprises the detection and picking of tiles in a pile of tiles as delivered by the supplier. The major challenge of the application is the arrangement of tiles – being tightly stacked next to each other with minimal contrast between the tile edges and their top surfaces. Another challenge resided in the height of the pile, which is dramatically changing during the bin picking process. This means that the focus area of the deployed 3D vision changes as well.Besides the Bin Picking Studio and PhoXi 3D Scanner from Photoneo, the application deploys collaborative robots UR5 and TM12.&nbsp;Discussion:The plug &amp; play and easy-to-use Photoneo system enabled getting the application ready within a few days instead of weeks. Another advantage of Photoneo solution is that it does not require any specific illumination.The case study is a proof-of-concept, successfully demonstrating how traditional manual labor can be reduced using automation solutions, freeing human workers for other, less monotonous and health-detrimental tasks.

The JAMK University of Applied Sciences uses Photoneo PhoXi 3D Scanner and Bin Picking Studio to test bin picking for external companies and their specific applications.

Bin picking application in a university lab

Partner:<a href="https://sk.volkswagen.sk/sk.html" target="_blank">Volkswagen Slovakia, a.s.</a>&nbsp;Problem:The customer Volkswagen Slovakia, a.s. decided to automate one of its car body production processes, which was performed manually before. The process started with production parts being loosely stored in a container on the floor. A worker took the parts from the container and inserted them into a jig. After that, an industrial robot took them from the jig to be further technologically processed.The goal of the new automation solution was to deploy an industrial robot for taking the parts directly from the container and inserting them into the jig. The solution was designed to ensure the stability and repeatability of the process.&nbsp;Solution:<a href="https://www.photoneo.com/phoxi-3d-scanner/" target="_blank">Phoxi 3D Scanner XL</a>The customer was looking for a solution from a local supplier of robotic vision solutions specializing in bin picking applications.Based on a 3D (CAD) model of the part, the solution identifies each part in the container, including its position and orientation. Then the robot picks the part with a gripper, adjusts its orientation, and inserts it into the jig.&nbsp;Discussion:The customer wanted to increase the degree of automation and reduce production costs. They decided on Photoneo PhoXi 3D Scanner based on its unique features, including high accuracy and resolution, fast scanning speed, industrial-grade quality, support, and other benefits the scanner provides.

Automated picking of parts from large bins and inserting them into a welding cell.

The customer decided to automate one of its car body production processes to increase the degree of automation and reduce production costs. They decided for Photoneo technology based on its high accuracy and resolution, fast scanning speed, and other qualities it offers.

Innovative picking in the automotive industry by Volkswagen

Partner:&nbsp;Daikin PilsenProblem:The plant in Pilsen produces over two million air conditioning units per year. A lack of manpower and attempts to minimize human errors are reasons why DAIKIN Industries Czech Republic focuses on process automation in their production plans fulfillment, with continuous attention to high product quality.&nbsp;In one of its assembly lines, there was a specific bottleneck in a mid-assembly quality-check process &nbsp;that required a new approach based on a high-quality 3D vision system – a test of the integrity of heat exchangers. The major motivation to automate the sensitive test and the challenge per se lied in the requirement for high preciseness during the inspection of heat exchangers. Because they are made of thin, fragile metal, &nbsp;human errors in the preceding manual inspection process occurred. The required precision of robot guidance in the planned automation solution was +/- 1 millimeter.&nbsp;Solution:<a href="https://www.photoneo.com/bin-picking-studio/" target="_blank">Bin Picking Studio</a> + PhoXi 3D Scanner model SThe Photoneo solution consists of a tailor-made application based on accurate localization and robot-camera calibration. The heat exchanger, first pressurized with helium, comes to a leak-detection cell&nbsp;on a conveyor belt, where it is positioned randomly.In the cell, the PhoXi 3D Scanner scans the object from two different positions to increase the reliability of measurement and the robustness of localization. The system detects the position of the heat exchanger and adjusts the predefined trajectory of the sniffing detector very precisely and carefully along a complex and fragile surface of the object in order to inspect its quality and notice potential helium leakage without damaging it. In addition, Photoneo simplified its robot-camera calibration process to such an extent that calibration can be done by a trained end-user operator without on-site presence of Photoneo’s specialists.&nbsp;Discussion:The whole solution is demanding in terms of working with glossy aluminum surfaces, the configuration, precision of the scanner, and localization software. Moreover, the component geometry of the pieces coming on the conveyor belt is often not identical, so a robust logic had to be implemented to reflect this. The robotic manipulation with the detector as a tool had to be very gentle and precise given the formability of the thin metal material of the parts.&nbsp;Photoneo’s team tackled a very limited workspace of the leak-detection cell in the brownfield deployment.&nbsp;The solution is installed in a production line with a variable just-in-time production plan which means that several types of heat exchangers are subject to a quality check, not just one. The system is extensible, i.e. even after the initial setup for a set of certain heat exchanger types, new ones may be added and probed later on.&nbsp;There is no programming involved and the change is doable only in configuration by a Photoneo specialist. The addition or alteration of the configuration for a particular type of heat exchanger does not affect the quality of service provided for other existing types.&nbsp;

Precise checking of heat exchangers for Daikin Czech Republic

The solution consists of a tailor-made application based on accurate localization and robot-camera calibration. PhoXi 3D Scanner scans the object from two different positions to increase the reliability of measurement and robustness of localization.

pick and place robots

Profiles