Flexible controls for mobile robots and compact machine cells
In industry, even elaborate processes such as the application of adhesive tape to parts with varying geometries are automated. For robotic taping systems, however, the feeding of tape material presented a pain point. With RoboTape, Innovative Automation has developed a platform with Beckhoff control technology and a remote feeding module, which increases productivity and enables flexible customization for different requirements.
The world of adhesives keeps expanding to accommodate applications with highly tailored tapes, foams and other products. However, automated tape dispensing systems have not kept up and offer little flexibility to adapt to wide-ranging industry requirements. Here, RoboTape offers a way out of the dilemma. Innovative Automation, a Canadian custom machine builder and systems integrator headquartered in Barrie, Ontario, developed the platform and then spun it off as a new business unit. Leveraging advanced robotics and flexible controls technology, RoboTape delivers a solution suitable for everything: from B2B with a focus on the automotive industry through to large CPG companies, and all sorts of part geometries and adhesive types.
The entry-level solution of the RoboTape business unit in Newmarket, Ontario, is the compact, “RoboTape Lite” work cell. The RoboTape standard cell with an enclosed industrial robot supports a higher production throughput. The impressive capabilities led to a collaboration with 3M, a leader in industrial bonding solutions, and the development of the RoboTape™ System for 3M™ Tape.
Tape feeding from outside of the machine cell
The main pain point of existing solutions was robot size and maneuverability, because most systems place the tape spool at the end of the robot arm, along with an empty spool to catch the waste liner. Also, operators have to wait until the systems run out of tape, put them into a safe machine state, and enter the cell to add more, which takes away valuable production time.
“We came up with the idea of a remote feeding module that positions the spool outside of the work cell. That’s now patent pending worldwide,” says Zac Cutt, Research and Development Group Leader at Innovative Automation. “It also helps with the robot sizing issue, allows for larger spools and increases system uptime. This is why big automotive clients are latching onto it; it's currently the only solution that actually solves the entire problem.”
RoboTape catches and chops up the waste liner at the remote feeding module. The design optimizations drastically reduce the size of the robot needed, Michael Lalonde, Co-owner and President of both RoboTape and Innovative Automation explains: “We were aiming for the 10-kilogram robot class, so keeping the applicator tool light and compact was a top priority. This allows the tool to work in tighter areas and to reduce the overall size and cost of the work cell. These are all things our customers have been requesting.”
Before RoboTape was ready for use, a variety of challenges had to be removed first. The team had to effectively accommodate a wide range of robots and enable the solution to continuously adapt to new parts for taping processes and gather massive amounts of sensor data for rapid processing.
New Automation Technology facilitates implementation
“In 2020, we created a decision matrix comparing four control system providers,” Zac Cutt recalls. “We compared all of the technologies offered, the benefits, the costs, etc., and ultimately, we decided that Beckhoff provided the best fit for the RoboTape system.” Innovative Automation worked closely with the sales and support teams at Beckhoff Canada. Regional Sales Manager Paul Pierre and Application Engineer Jim Fallowfield offered advice and technical assistance on everything from TwinCAT 3 automation software programming to EtherCAT networking. This helped accelerate design, commissioning and operation.
Sean Robillard, Controls Department at RoboTape, appreciates the user-friendly software approach: “With a TwinCAT project, we have one folder with files for each PC-based controller. Within that code, we have all safety and I/O functions, so development of the system can be easily managed. This helps us implement different recipes, which tell the system how much tape to dispense and how quickly.”
“Operators can view all their inputs and outputs, toggle cylinders, lights and sensors, and adjust other aspects of the machine,” says Josh Vander Doelen, Project Manager at RoboTape. “That’s all bundled into the same TwinCAT package, so it speeds up engineering and keeps the HMI design clean.”
A CP6706 economy built-in Panel PC from Beckhoff offers ample processing power for the application. It is equipped with a dual-core Atom® processor, 4 GB RAM, 40 GB CFast card and a 1-second uninterruptible power supply (UPS). The IPC includes a 7-inch touchscreen for operator interface and in conjunction with TwinCAT automation software is ready for cloud connectivity right out of the box.
The control system utilizes the EtherCAT industrial Ethernet system for real-time communication to the robot and other field devices. The openness of EtherCAT with regard to integrating other protocols helps the RoboTape team connect a vast range of different robots and third-party devices such as sensors and encoders in customer facilities. “For example, we use many IO-Link sensors to gather as much data as possible,” Zac Cutt adds. “We simply add EL6224 IO-Link terminals from Beckhoff to the main I/O segment as we need more sensors.”
With TwinSAFE for system-integrated functional safety, the platform can best protect plant personnel and equipment, according to the RoboTape experts. The remote feeding module will enter a safe state when operators open its enclosure. This level of safety is required because inside the feeding module a cutting blade utilized to chop the spent liner and other pinch points are contained. For that purpose, TwinSAFE safe input and output terminals are used that can be connected directly to the door of the robot cell, light curtains or floor mats, for example. These TwinSAFE I/O terminals use Safety over EtherCAT (FSoE) for safe communication over the EtherCAT network using a “black channel” approach, and in this way eliminate the need for the conventional and complex hardwiring between safety devices.
Support for end users
“Our systems average eight hours of runtime before refills, but this can be greater depending on the material,” Zac Cutt says. “For instance, one customer processed 14,000 feet (more than 4,000 m) of felt on a single spool, so they're making enough parts for about 2,000 cars a day and only changing spools once a week.”
Another Tier 1 automotive supplier shrank the overall footprint of its assembly area by removing two manual taping stations. In addition, it reduced labor requirements at a time of skills shortages. As a result, the customer saved roughly 225,000 Canadian dollars per year on adhesive applications in one plant.
“Our new IoT capabilities can allow us to see which machine modes are activated and for how long. So if a system is in service mode for long periods of time, it could indicate it needs maintenance or that a particular operator requires more training to meet uptime goals,” Zac Cutt says. “We can see the machine’s overall equipment effectiveness (OEE), along with metrics like internal and ambient temperature, to continue to optimize and improve reliability.”
“The consistent support and availability are reasons why Beckhoff has proven to be a great choice, and we’re excited to continue working together in the future,” Michael Lalonde says.