Summary
The challenge
Until recently, the biggest challenge for companies looking to automate the finishing of plasma and oxyfuel cut sheet metal parts was the need to program the robot to handle each different product. The time and complexity involved made it difficult to produce small batches or single pieces cost-effectively. Teqram’s EasyGrinder solution solves the problem.
The solution
Teqram’s solution uses EasyEye 3D vision sensors and intelligent robot control to enable the robot at the heart of the EasyGrinder system to work autonomously by recognizing and manipulating different product geometries as needed. It means that selecting, positioning and changing tools and grippers for picking up and machining different parts is completely autonomous.
The application
The robot collects each item from the pallet, scans it and selects the right process, which typically involves grinding and deburring, as well as removing any layers of slag and oxide. It then flips the part over and stacks it on another pallet.
Ancofer Stahlhandel is a German steel stockholder and service center for flame-cut sheet metal parts. Like engineering firms around the world, recruiting skilled workers is a challenge and the company realized that there was one area of its operations where people were especially reluctant to work – deburring and finishing. Deburring is hazardous and physically demanding, using noisy grinding equipment that poses short- and long-term risks to health and safety. Automation was the answer and Ancofer turned to Dutch system integrator Teqram for a solution.
Built around an ABB IRB 6700 robot, Teqram’s EasyGrinder system not only improves working conditions but also boosts Ancofer’s competitiveness by providing added flexibility and consistent, predictable quality. The added power of a robot compared to a human operator also increases processing speed and reduces abrasive consumption, making it a cost-effective option.
“The robot is optimal for our process since it can be programmed to handle both large and small product runs, giving us the ability to easily scale our production according to demand,” says Ancofer sales manager Lars Kerlin.
“It no longer requires lengthy programming,” confirms machine operator, Christopher Janko. “The robot will scan the products and determine what needs to be done.”
EasyGrinder is able to process short runs and even one-off parts without reprogramming thanks to its patented EasyEye 3D vision sensor and intelligent robot control.
The main EasyEye system configures the overall cell and provides the robot with 3D coordinates that describe its surroundings. It is also used to recognise each part. Additional 3D vision is incorporated in the robot’s gripper to provide more precise measurements of each part’s contours.
The next piece of the puzzle is a patented system within the robot’s tools to measure the tilt of the tool and provide real time information about how the tool is moving. This provides more help in monitoring the precise contours of the part as the grinding process proceeds. There is a separate system based on counterweights that helps the robot understand how much pressure needs to be applied.
The first robot started operating at Ancofer in November 2023 and the company has subsequently installed a second.
EasyGrinder is already delivering improved safety and product consistency, but Teqram says the next challenge is to work towards deburring twice as fast as human operators. At the moment, EasyGrinder is quicker than people at processing some parts and slower for others, working around 5 to 10% faster on average. The robots must operate in tough, industrial environments where lighting conditions may not be ideal. That makes it a tough challenge for vision systems.
ABB recognized Teqram’s innovative EasyGrinder solution at last year’s ABB Value Providers Awards and the integrator has now sold more than 10 systems to companies around the world.
