Switching to Robotics

8/7/2019 Switching to Robotics

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Switching to RoboticsSwitching to RoboticsSwitching to RoboticsSwitching to Robotics

p r e s e n t s

FRP and Polyurethane ApplicationsFRP and Polyurethane ApplicationsFRP and Polyurethane ApplicationsFRP and Polyurethane Applications


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Why Automate?

The constantly increasing cost of doing business

Increasing material costs

Increasing labor costs

The Requirement for better production processes

Market demand for increased quality

Market demand for increased throughput

Business demand for improved bottom line

Todays exposure and emission regulations are forcing

open mold formers and hot tub/spa manufacturers to examine

alternative application techniques

Switching to Robotics


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Why Automate?


Material Cost

Labor Cost

Warranty Cost

Quality

ALL of These Issues Increase the Cost Per Part ProducedALL of These Issues Increase the Cost Per Part Produced

A Robotic Application of your material can:

Reduce per part material usageImprove product quality and consistency

Reduce part re-work and warranty cost

Re-allocate direct labor

- Spray Process

- Rollout Process

Emission Regulations


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Why Automate?


Environmental and exposure regulations are driving

manufactures to investigate alternative methods of

material application.

Consider the following video:

Stronger environmental emission

regulations drove this customer to

automate their manufacturing process.The result is a more competitive

manufacturer that also reduced emissions.

Please Click on Video #1


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Benefits Of Robots


Material SavingsRepeatable robot paths and gun triggering means the material

application will be repeatable and consistent

Overspray is Reduced

Gun Triggers are More Precise

Material Consumption Goes Down



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Material Savings - Case Study

Whirlpool and Spa Manufacturer

BeforeBefore After After Total MaterialTotal Material Total MaterialTotal Material OversprayOversprayChopChop ChopChop On PartOn Part UsageUsage QuantityQuantity PercentPercent

Shell 1Shell 1 38#38# 83#83# 45#45# 47.2#47.2# 2.2#2.2# 4.64.6

Shell 2Shell 2 38#38# 82.5#82.5# 44.5#44.5# 47.1#47.1# 2.6#2.6# 5.55.5

Shell 3Shell 3 38#38# 83.0#83.0# 45#45# 46.9#46.9# 1.9#1.9# 4.04.0



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Benefits Of Robots

Without Robot:

+10%

-10%

Typical weight variance graph- pull weight / part weight each point

represents one job- all measurements in relationship to ideal nominal

weight

With Robot

+10%

-10%

+1.5%

-1.5%

Without Robot


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Benefits Of Robots

Product Quality

Automated robotic application of material brings consistency to

the spray out process.

Most advanced robotics systems

include fluid delivery monitoring

which alert plant personnel when

material delivery is out of a desiredtolerance.



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Benefits Of RobotsProper application of material requires consistent material

delivery, consistent gun triggering and maintaining a consistent

gun target distance.

Robots provide all of these requirements

Additionally, proper application of these materials eliminates

product cracking, part re-work due to appearance concerns and

fiber bleed through.

These problems directly affect warranty costs, which also affect

the bottom line. Robotic application of materials can help the end

user get these product variables under control, reducing long term

warranty concerns.


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Benefits Of Robots

Labor and Environmental ConsiderationsManual spray out of the FRP process requires an employer to provide

equipment for an employee to work within a hazardous environment.

Robots can easily work within a hazardous environment; this allows

the employer to limit the exposure direct laborhas with airborne chop

emissions.

With removal ofhumans from the actual spray environment, booth air

can be recirculated, and airborne concentrations within the booth can

remain at a higher level releasing less emissions in the air. This might

allow the end user to add a rotary concentrator to further reduce

emissions.


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How It WorksHow It Works




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Customer andCustomer and

SupplierSupplierRequirementsRequirements


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Customer Requirements

One Dedicated Robot Operator Per Shift

Optimal operatorhas knowledge ofFiberglass Chop & Polyurethane Applications(fluid delivery equipment, mold variations,etc.)

Operator will learn robot programming &error recovery

Customer / Supplier Requirements



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Customer Requirements

All robot operators should attend an

Operations and Programming Class offered byrobot supplier

Dedicated project manager for system start-up




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Supplier Requirements

System supplier should have extensive

knowledge of robotic Fiberglass Chop andPolyurethane applications

Experienced personnel in ProjectManagement, Installation, and Engineering

Product and software packages dedicated to

specific markets (R&D)Established market base



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Conclusion

Robotic automation can reduce material usage and improve part

quality.

Robots can remove personnel from hazardous locations and also

increases material application consistency.

Robots can help a manufacturer reduce employee exposure to

styrene emissions.

Robots can improve product manufacturing process.


Documents

Switching to Robotics