Transforming Semi-Automated Cobot Operations into Full Production Line Integration

The Challenge Behind the Solution

A manufacturing facility had invested significantly in collaborative robot technology to enhance their production processes, but their cobot-assisted application system still required excessive manual intervention. The existing setup included an Omron collaborative robot for product application, but operators had to manually position products, manage UV curing processes, and coordinate material flow between stations. The dilemma was clear: how to maximise the return on their automation investment whilst eliminating production bottlenecks and reducing labour dependency.

The Critical Issues

Production operations were hampered by four fundamental challenges:

• Inadequate Automation: The existing cobot PLC did not permit servo control, severely limiting automation capabilities and requiring constant manual intervention
• Manual Operations: The lack of automatic indexing and positioning led to increased manual handling, reducing efficiency and creating potential quality inconsistencies
• Integration Challenges: Coordinating new components like UV lamp tunnels and pneumatic elements required precise timing that manual operations couldn’t consistently achieve
• Operational Bottlenecks: Manual product handling between application and curing stages created delays and limited overall production throughput

A Smarter Approach to Control

Rather than applying piecemeal automation improvements, we focused on a collaborative approach to develop a comprehensive servo-based control solution. Working closely with the production team, we designed a system that would integrate existing cobot capabilities with new automated material handling and process control.

Core Solution Elements:

• Design and manufacture of custom servo-based indexing system for automatic product positioning
• Integration of UV lamp control with precise timing coordination
• Modification of existing HMI for operator-friendly automatic operation control
• Implementation of comprehensive safety systems for unmanned operation

Key System Components

Servo-Based Control System:

• Enclosure: 200mm high, 800mm wide, 400mm deep in mild steel construction
• Servo Motors: 2 x Omron servo motors for infeed and outfeed conveyor control
• PLC: Omron PLC with integrated servo control capabilities
• Safety Systems: PILZ safety relay module for secure operations

Control Interface:

• HMI: Modified existing human-machine interface for automatic operation control
• UV Lamp Integration: Automated UV lamp tunnel with PLC-controlled timing sequences
• Pneumatic Elements: Coordinated pneumatic positioning systems

Pricing Information:

• Components purchased: £18,500
• Design and manufacturing: £6,000
• Installation and commissioning: £3,000
• Total project cost: £28,000 (excluding VAT)

How the System Functions

Automatic Indexing Process: The servo motors precisely index products at predetermined lengths set through the HMI interface. This automated positioning ensures consistent product placement for the cobot application process, eliminating manual handling variations and improving repeatability.

Cobot Application Sequence: Once products are automatically positioned, the cobot applies material according to its pre-programmed script. The servo-controlled indexing ensures products are in exactly the correct position every time, allowing the cobot to operate with maximum precision and consistency.

UV Lamp Integration: Following product application, the PLC automatically requests UV lamp operation for a precisely controlled time period. This timing coordination ensures optimal curing without the delays and inconsistencies of manual lamp activation.

Outfeed Processing: The outfeed conveyor automatically moves completed products away from the cobot work area, maintaining continuous flow and preventing accumulation that could disrupt the automated sequence.

Key Technological Advantages

Precision Through Servo Control: Servo motor technology provides precise positioning control that manual operations simply cannot match consistently. The system can achieve positioning accuracy within fractions of a millimetre, ensuring optimal product application every time whilst eliminating the variability inherent in manual positioning.

Integrated Process Timing: Rather than relying on operator judgement for UV curing timing, the PLC coordinates all process steps automatically. This integration ensures optimal curing cycles whilst preventing under-curing or energy waste from excessive exposure times.

Enhanced Safety Architecture: The PILZ safety relay system provides comprehensive protection for unmanned operation, monitoring all critical functions and ensuring safe shutdown if any anomaly occurs. This allows operators to focus on other tasks whilst maintaining complete operational safety.

Measurable Improvements

• Reduced Manual Intervention: Eliminated 90% of manual handling operations, freeing operators for higher-value tasks
• Improved Process Consistency: Automated positioning and timing delivered 95% reduction in application variations
• Increased Production Throughput: Continuous automated operation increased output by 40% compared to manual coordination
• Enhanced Quality Control: Consistent UV exposure and application positioning reduced defect rates by 60%

Frequently Asked Questions

How does the servo control system improve upon the original cobot setup?

The original cobot system required manual product positioning and timing coordination, which created bottlenecks and inconsistencies. Our servo control system provides precise, repeatable positioning that allows the cobot to operate at its full potential. The servo motors can position products to within 0.1mm accuracy, compared to the 2-3mm variations typical with manual positioning. Additionally, the automated timing coordination ensures that UV curing cycles begin immediately after application, eliminating the delays that occurred when operators had to manually activate curing systems. This integration transforms the cobot from a semi-automated tool requiring constant supervision into a fully automated production cell.

What safety considerations were addressed when implementing unmanned operation?

Safety was paramount when transitioning from operator-supervised to fully automated operation. We implemented a PILZ safety relay system that continuously monitors all critical functions including servo motor positions, UV lamp status, and emergency stop circuits. The system is designed with fail-safe logic, meaning any component failure results in a safe shutdown state. Light curtains protect the cobot work area, and all access points have interlocked guards. The UV lamp system includes automatic shutdown if personnel access is detected. Emergency stops are positioned at multiple locations and will immediately halt all operations whilst maintaining product and equipment safety. All safety systems comply with CE marking requirements and relevant machinery safety standards.

How does this solution handle different product sizes and specifications?

The servo-based indexing system stores multiple product profiles, each with specific positioning parameters, application timing, and UV curing requirements. When production changes to a different product type, operators simply select the appropriate profile from the HMI touchscreen. The system automatically adjusts servo positioning distances, cobot application patterns, and UV lamp timing accordingly. For new products, the system allows operators to create custom profiles through a guided setup process. This flexibility eliminates the need for manual recalibration when switching between products and ensures consistent quality regardless of product specifications. The system can store up to 50 different product profiles with instant changeover capability.

What ongoing maintenance and support does this automated system require?

The servo-based system requires routine maintenance similar to other industrial automation equipment. Servo motors need periodic lubrication checks every 6 months, and the UV lamps require replacement every 8,000-10,000 operating hours depending on usage intensity. The PLC system includes built-in diagnostics that alert operators to any performance degradation before failures occur. We provide comprehensive maintenance training for facility staff and offer annual service contracts that include preventive maintenance, software updates, and priority technical support. Remote diagnostic capabilities allow us to troubleshoot many issues without site visits, minimising downtime. Spare parts availability is guaranteed for a minimum of 10 years, and we maintain local stock of critical components for immediate replacement if needed.

The Long-Term Impact

The transformation of this cobot installation demonstrates how existing automation investments can be maximised through thoughtful integration and control system upgrades. By addressing the coordination and timing challenges that prevented full automation, this project shows that companies don’t always need to replace existing equipment to achieve significant productivity improvements.

This project serves as a blueprint for how manufacturing facilities can evolve their automation strategies incrementally, building upon existing investments whilst achieving dramatic operational improvements. The success of this servo-based integration approach has established new possibilities for cobot applications and serves as a model for future automation enhancement projects in similar industrial applications.