flexible robotic cell for small series: 🤖 Flexible robotic cell for small series: Finally, even the production of one pallet is profitable
🔹 Introduction: A Problem Called Small Batch
Traditional automation was designed for mass production. A single changeover to a different type of part took hours. Today's market, however, demands the opposite: high variability and small series (so-called high-mix, low-volume). This applies to machine operation (CNC), palletizing and quality control.
A flexible robotic cell, often built around collaborative robots (cobots) and vision systems, is a direct response to this trend. Its main goal is to minimize set-up time and ensure that automation pays off even for a single-container order.
🔹 Main part: Pillars of rapid adaptability
A flexible robot cell for small series production is not based on the speed of the robot itself, but on the speed of its adaptability. This is achieved by integrating three key technological pillars.
1. Collaborative Robot (Cobot) – Easy Programming
The basis is usually a lightweight and safe cobot (e.g. Universal Robots) that does not need expensive safety fencing.
- Fast learning: Programming is done using an intuitive graphical interface or by leading the robot. The operator simply grabs the arm and shows it where to pick up the part and where to place it.
- Templates: For frequently repeated tasks (e.g. palletizing boxes), software templates are used, where you just enter the dimensions of the new product and the robot calculates the path itself.
2. Visual system and smart grippers
The biggest delay in small batches is caused by the need to change end effects (grippers) and positioning fixtures. The smart cell minimizes these manual interventions:
- Vision for orientation: Instead of expensive and rigid positioning fixtures, 2D or 3D camera systems are used. Before starting work, the robot takes pictures of the new parts itself, determines their exact position and orientation, and compensates for deviations. This eliminates mechanical replacements.
- Universal grippers: Instead of custom-made grippers, a universal solution is chosen (e.g. OnRobot VGP20 vacuum gripper, or flexible three-finger gripper), which can grip a wide range of parts without the need for replacement.
- Quick Changer: If a gripper change is necessary, the automated Quick Changer shortens it to tens of seconds.
3. Mobility – The cell goes to work
The highest level of flexibility is represented by mobile robotic cells. The robotic arm is mounted on an autonomous mobile robot (AMR). The cell is therefore not fixed. It can operate a CNC machine in hall A and, after completing a series, it moves alone (or with an escort) to the packaging line in hall B, where it starts palletizing another product. This flexibility allows the sharing of robotic capacity between multiple workplaces.
🔹 Economic benefit for small series (ROI)
The flexible cell changes the economic model of small batches. Here are the key benefits:
- Re-armament reduced from hours to minutes thanks to visual systems and software templates.
- Increased resource utilization, as the robot will service 3 different machines per day (thanks to mobility).
- Releasing qualified personnel (e.g. CNC operators) from routine operations.
- Faster return on investment (ROI) because you automate a larger portion of your overall portfolio of orders, not just the largest ones.
🔹 Conclusion: The future belongs to agile
The era of expensive, slow and rigid automation is over. A flexible robot cell is the key to staying competitive in a market with high demand for individualization. The integration of cobots, vision systems and mobile platforms will ensure that automation pays off even for the smallest batch sizes.
Are you looking for a solution to automate high-variability production? Visit svet-robotu.cz and find out how to adapt a flexible cell to your high-mix, low-volume production.