UR+ platform delivers access to automate legacy machines with collaborative robots at All Axis MachiningAll Axis Machining struggled to automate the operation of old machinery. When the company discovered the open integration architecture through the Universal Robots+ platform it was quickly able to automate six different operations with collaborative robots. The deployment was so successful that All Axis started a new business, offering UR cobot integration services to other machine shops.

skeleton shift with only half the machines running. It was costing me orders that I couldn’t get to my customers on time.”

A major obstacle in automating operations was the fact that All Axis’ machines were legacy equipment with no direct interface for traditional industrial robots. “Also, an industrial robot requires a fence around it, we weren’t ready to give up floor space - or more importantly; be locked into using the robot for one task only,” explains Kuzmin.

No hidden integration costsHaving exhausted their options with conventional robotics, the Texas machine shop discovered collaborative robots could be a possible solution. “We got a demo of Universal Robots and

“Last year, we could not even spell robot,” says Dave Perkowski, General Manager at All Axis Machining as he walks the shop floor where numerous collaborative robots are now hard at work automating CNC machine-tending, sanding, deburring, part inspection, laser marking and wire EDM. “We had no actual robotic integration and automation. Being able to immediately start interfacing cobots with our machines has been unbelievable.”

All Axis started to look for automation as they faced a lack of available manual labor, causing unwanted downtime on machinery. “It drove me pretty crazy when all the guys were out to lunch, and none of the machines were working,” says owner of All Axis Machining, Gary Kuzmin. “After 5pm, we’d have a

CASE STORY: ALL AXIS MACHINING

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quickly realized that these cobots offered easy integration through the controllers of our old machines,” recounts the machine shop owner. The communication between the UR cobots and All Axis’ machines is made possible through the UR+ platform, that through a free Software Development Kit (SDK) allows users to develop their own plug-ins, so-called URCaps, that integrates the control of the entire application right through the cobot’s own teach pendant.

“Universal Robots has done a fantastic job of making this solution available to shops like ours,” says Perkowski. “The operating system is open, I’m not locked into a proprietary environment. We’re basically given this cookbook with an easy way to expand communication,” he says and explains that All Axis uses protocols such as TCP/IP, Ethernet, Modbus and Profinet connecting cobots and machines. ”From a technology perspective it’s heaven to have all these capabilities and take our current systems and integrate without any other assistance,” says the general manager, adding there are no hidden costs. “An advantage is we don’t have to pay special license agreements, it all comes with the purchase of the UR cobot. We simply sign up on the UR website to become a developer, and we download the elements we need.”

The UR+ platform also addresses the trial and error that associated with equipping the robot arm with peripherals such as end-effectors, force sensors, vision cameras and other accessories. The platform features a showroom with more than 100 products certified to work seamlessly Universal Robots.

“We were able to browse the showroom and quickly bring UR+ grippers and tool changers off the shelf and onto the cobots,” says Kuzmin.

60 percent profit increaseAs with any machine shop owner, he is always worried about the bottom line. When All Axis got its first UR10 cobot, the company had a job slated to take four to five months of run-time on one machine with the current staffing. “We couldn’t hire any additional staff at that point, so we took the robot, put it on the CNC machine and actually delivered that part almost two and a half months early because of all the additional machine time that we had,” recounts Kuzmin.”We saw a 60 percent profit increase on that job alone. ROI was about a four month return. Our spindle up-time has gone from about eight hours a day to about 20 effective hours.”

All Axis also soon discovered that the 50 microns accuracy of the UR10 was crucial in terms of precise insertion in laser marking and CNCs as well as in sanding and deburring. “Our sanding used to be all manual and lines from tool marks could not always be avoided,” says Kuzmin. “With the UR10 that part came out perfectly straight; in fact, the customer called us up and said they were impressed and wanting to know what we did different.”

Empowering employeesWhen the machine shop first researched the cobots, management was curious to find out how different the

CASE STORY: ALL AXIS MACHINING

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All Axis developed a 7th axis pedestal stand for the UR10 cobots so they can easily be moved between different tasks on the shop floor.

programming and operation would be, specifically for operators with no prior experience. The company had the employees go through the UR Academy, consisting of free, interactive online modules that teach basic programming and set-up. “We had an elderly operator doing the sanding, which requires a lot of muscle,” explains Kuzmin, who was watching the operator on a monitor. One day he saw the operator, who had just completed some basic training at the UR Academy, pick up the cobot’s teach pendant to start programming it to sand the part. “I’ve never been more proud to see one of our employees learn a brand-new technology. This is really empowering and is going to improve his whole lifestyle and earning capability as well,” says the shop owner

One cobot - many tasksAll Axis is not a high volume shop. The company typically runs more than 20 different parts per day and needed quick change-overs; both between tools at the end of the robot arm and in terms of moving the robot between machines to be tended. “We need to achieve change-overs in about 5-10 minutes at the most. The UR+ program allowed us to find products for the robot that

Five months, five cobot installations. That was the timeline at All Axis Machining that now automates CNC machine-tending, sanding, deburring, part inspection, laser marking and wire EDM with the UR10 collaborative robots from Universal robots.

all had quick disconnects. The platform even gave us the tools to develop some ourselves,” says Perkowski, adding that All Axis has also developed mobile platforms that now wheel the cobots between jobs.

All Axis Robotics is bornHalf a year into the cobot automation project, All Axis management realized their newfound expertise could easily be extended to other machine shops facing the same hurdles. “We suddenly saw a whole new business emerging,” says Kuzmin who created a new company, All Axis Robotics, dedicated to the integration of turnkey UR cobot solutions in the metal fabrication industry. ”When a company calls us now, we can come in, look and evaluate what their needs are, and on any of their equipment—no matter how old it might be—we can probably implement a robot into their operations,” says the shop owner, adding that people might wonder why he would be helping out the competition. “What we compete for is labor. There’s plenty of business out there for all of us to have,” he says. “Integrating cobots into legacy machines is what will really drive manufacturing in the United States.”

CASE STORY: ALL AXIS MACHINING

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A COMPLETE RANGE OF

COLLABORATIVE ROBOTS

Meet the UR Cobots:Universal Robots is a result of years of intensive research in robotics. The six-axis robot arms weigh as little as 24 lbs. with reach capabilities of up to 51 inches. The product portfolio includes the collaborative UR3e, UR5e and UR10e robot arms named after their payloads in kilos.

Repeatability of +/- .003mm allows quick precision handling of even microscopically small parts. After initial risk assessment, the collaborative Universal Robots can operate alongside human operators without safety guarding. If the robots come into contact with an employee, the built-in force control limits the forces at contact, adhering to the current safety requirements on force and torque limitations.

Intuitively programmed by non-technical users, the robot arms go from box to operation in less than an hour, and has the fastest payback in the industry - as little as 34 days in the USA.

UR3e UR5e UR10e

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How to get started with cobots in 10 steps Ready to find out how cobots can benefit your production? This ebook will help you kickstart your first cobot project, stepping you through decisions on:

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• Throughput• Reach & Payload• Parts & Presentation• Connectivity & Integration• Grippers & End effectors• Programming

... and much more

6 Grippers & End Effectors

An end effector is mounted on the robot arm to interact with parts and machines. It can be a suction cup or two-fingered gripper to pick up parts, a spot-welding tool or paint sprayer, or almost anything else you can imagine to meet your application needs. A range of suction cups and grippers are widely available for cobot arms, and for specific applications you may be able to create custom tools using 3D printers or specialized suppliers.

➜ Can you use a single, flexible end effector for multiple processes, or do you need individual tools for each job? Off-the-shelf tools can be simple and cost-effective, but a custom tool might be just what you need —even though it may add complexity.

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Consistent parts, easy to pick up with standard grippers

Variable part sizes and shapesor custom end effectors

1 Throughput

Similar throughput speed as human workers

Cobots typically perform a simple process at about the same pace as a human worker, so consider automating operations where you’re already comfortable with the throughput you’re achieving manually. Of course, a cobot can continue the process non-stop — even around the clock — so you will likely see an increase in productivity. But cobots also offer consistent, dependable output that frees human workers from low-skill jobs so they can work on higher-value activities.

➜ Planning to run your cobot at higher-than-human speeds? You may need other systems to assure the safety of human workers. You may also need to teach the robot reasonable paths and pay attention to payloads.

Higher speed adds complexity to risk assessment

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4 Collaborative with Humans

Collaborative robots are designed to work safely side-by-side with human workers, but a risk assessment will help define the appropriate human-cobot interaction for your situation. Just as with humans working together, safety concerns include moving parts with sharp edges, or using a cutting tool, welding torch, or grinding wheel. An ideal collaborative environment is where people do what they’re good at — such as overseeing operations — while the cobot does the repetitive, manual, and possibly dangerous work of handling parts and machines.

➜ If the cobot needs to move at high speeds or the job raises other safety concerns, you may need a light curtain or safety scanner to slow or stop the arm when a human enters its work space.

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Workers and cobot have defined spaces and interaction

Cobot speed, parts, or end effectors that require additional safety measures

7 Mounting & Fencing

In the simplest applications, the cobot is mounted in one place and stays there, doing the same thing over and over. Lightweight and easy-to-program cobots can also be moved between processes — even mounted on a rolling cart to make that convenient. Just keep in mind that each time the cobot is moved, it needs to be localized to its work space so that parts and machines are where the cobot expects them to be. Programs can be stored on the teach pendant and reloaded by the press of a button.

➜ Most cobot applications don’t need additional safety guarding or sensors, depending on your risk assessment. Built-in features adhere to current safety requirements on force and torque limitations, so the cobot automatically stops operating and doesn’t cause bodily harm if it collides with a person.

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Robot mounted in one place, moving at typical human speed

Robot moves, operates at high speeds, or requires additional safety precautions

8 Environment

Cobots work in almost any environment that humans can work in, without complaining about temperature, noise, or dirt. At the other extreme, you can also find cobots that can work in hygienic environments or are even cleanroom-certified. But like any equipment (or human workers, for that matter), cobots in extreme environments may need added protection.

➜ Protective covers protect the robot arm from temperature and humidity extremes, fluids and corrosive atmospheres, and particulates such as grit, dust, or debris. These covers are often available off-the shelf, but the more extreme the situation, the more complex it is to automate.

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Standard work environment for human workers

Extreme environments or applications with hygienic or cleanroom requirements

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