What are Assembly robots and how do they work?

Assembly robots (or Assembling robots) are automated machines that can independently perform repetitive tasks on production lines. They are programmed to grasp, move, and manipulate components with precision to assemble products.

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How do Assembly robots work?

Assembly robots operate based on coded instructions that detail the required tasks and motions. They utilize Six-Axis robotic arms fitted with grippers to grasp and manipulate components. Advanced sensors and vision systems can guide the robots to the correct locations and orientations.

Once in position, the robot can perform actions like:

1. Picking up components and moving them between workstations
2. Fitting parts together or affixing them in the proper alignment
3. Applying adhesives, sealants or welding materials
4. Securing components using mechanical fasteners like screws, bolts or rivets
5. Testing or inspecting assemblies at each stage of the process
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Assembly robots can work continuously without breaks, at consistent speeds, and with a high degree of accuracy. They minimize human error and maximize productivity while bringing a much higher degree of consistency and predictability to output planning. Implementing assembling robots may require an initial capital investment, but can achieve long-term cost savings through increased efficiency, improved quality, and reduced waste.

Assembly robots are transforming manufacturing by handling dangerous, repetitive and physically taxing jobs. They are an innovative solution that helps companies optimize operations, gain a competitive advantage, and meet increasing market demands. The future points to even smarter, more dexterous robots that will work alongside human technicians as collaborative co-workers.

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The benefits of using Assembly robots

The implementation of Assembly robots in factories and manufacturing facilities provides several significant benefits:

• Increased productivity and efficiency. Robots can operate 24 hours a day, 7 days a week without breaks, increasing productivity and reducing waste. They are also able to perform highly repetitive tasks with a high degree of accuracy and precision. Multiple robots can easily be overseen by a single operator.
• Improved quality control. Robots can detect defects with a high level of sensitivity using integrated vision systems and sensors. They consistently produce products of uniform quality and can be programmed to perform quality inspections during the assembly process.
• Reduced costs. Although the initial investment in robots and automation equipment can be substantial, the long-term cost savings are considerable. Robots can typically produce exponentially more than an equivalent human worker. They also have lower error and defect rates which reduces costs associated with waste, rework, and recalls.
• Improved workplace health and safety. Robots can take over dangerous, hazardous, and physically demanding jobs that can cause injury and health issues in human workers. They help create a safer working environment by reducing accidents and exposure to toxic materials or sharp tools.
• Increased competitiveness. The precision, speed, and cost-efficiency of robotics give companies that implement them a competitive advantage. They can consistently produce higher quality goods at a lower cost in less time, allowing them to gain market share, increase sales, and boost profits.
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In summary, Assembly robots provide significant and measurable benefits to factories and manufacturers. With advancements in Artificial Intelligence and robotics technology, their potential is enormous - the future of factories which adopt assembly looks extremely promising.

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Assembly robot applications in various industries

Assembly robots are transforming how products are manufactured in factories across various industries. 

Automotive industry

Probably the industry best known for the use of robotic assembly, automakers frequently use Articulated robots to handle the dangerous and repetitive tasks of welding, painting, and moving heavy car parts. Robots improve worker safety, product quality, and production efficiency. Assembly robots can work 24 hours a day, 7 days a week without breaks, enabling just-in-time manufacturing.

Electronics industry

Electronics companies rely on precision Assembly robots to manufacture everything from smartphones to televisions. Robots excel at assembling tiny components and soldering intricate circuit boards with a high degree of accuracy and precision that far surpasses human capabilities. Robots eliminate the possibility of human errors or variations that could impact product quality and performance. 

How to choose the right Assembly robot for your factory

When choosing an Assembly robot for your factory, several factors should be considered to find the optimal solution for your needs.

Type of Assembly

Select a robot and end-effector combination designed for your specific assembly task. Options include:

• Pick and place robots for moving and manipulating components.
• Welding robots for fusing materials through heat application.
• Painting robots for applying coatings to products.
• Other more specialized robots for gluing, riveting, etc.

Payload capacity

• Determine how much weight the robot needs to lift and maneuver. Robots offer payloads from a few kilograms up to 500 kg or more for heavy-industrial applications. Most assembly applications can be covered by a payload of 10-15 kg, so a robot like RO1 with an 18 kg payload is a versatile choice. Choose a robot rated for your required payload to avoid overloading. Remember, the weight of your end-effector and any other accessories attached to the robot will count towards this payload.

Reach and degrees of freedom

• Consider the size of components and workspace. Robots provide different reaches, numbers of joints and ranges of motion. A SIx-Axis articulating arm offers maximum flexibility while a 4-axis arm may suit simpler tasks. Select a robot with suitable reach and dexterity for your application.

Environment

• Evaluate the operating environment. Robots can work in clean rooms, hazardous areas, outdoor settings, and more. Collaborative Robots (or “cobots”) are specifically rated to work around humans, with technology like collision detection and emergency stopping. Choose a robot rated for your environmental conditions that provide the necessary sealing, heating, cooling or other protections.

Ease of programming

• Assess the complexity of programming for your task. Easier-to-program robots reduce deployment time using intuitive interfaces, while more complex robots offer advanced functionality at the cost of hiring specialist robotics programmers. If you’re going to be changing up your robotic tasks frequently, a no-code programming interface is key.

By carefully evaluating these key factors, you can choose an Assembly robot with suitable capabilities and the optimal level of sophistication for your factory’s needs. The right robot will allow fast, efficient and cost-effective assembly automation.

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How to integrate Assembly robots into your manufacturing process

To successfully integrate Assembly robots into your manufacturing process, several strategic steps should be followed:

Plan ahead

• Determine how Assembly robots can improve your operations and meet key business objectives such as increased production volume, higher product quality, lower costs, or improved worker safety. Is the cost-benefit analysis and return on investment clear?
• Evaluate your current assembly processes to identify which tasks are suitable for automation. Simple, repetitive tasks that require precision are often good candidates. Complex tasks which require human input or reasoning can quickly become oppressively expensive to implement.
• Research different types of Assembly robots and their capabilities to find options that would suit your needs. Compare prices, features, and space requirements to determine a budget and find the right solutions for your factory floor. Avoid overpaying for the capability you don’t need.
• Find a manufacturer or distributor who specializes in solutions engineering. The ideal partner will help you figure out the full solution for your needs (including the robot, end-effector(s) and accessories), take care of installation and programming and even provide an aftercare maintenance and support service.

Prepare the work area

• Ensure you have adequate space for the Assembly robots to operate, including room for conveyors or other equipment to supply and transport components and products.
• Install safety equipment like fences, sensors, and emergency stop buttons to protect human workers sharing the space if necessary. Consider purchasing a “Cobot” to reduce the external safety equipment required.
• Provide power sources and any utilities required for the Assembly robots to function. Note that end-effectors and grippers may require additional sources of power, such as pneumatic or hydraulic power.

Train employees

• Provide training to employees on how to properly and safely operate, interact with, and work alongside the Assembly robots. Clearly define roles and responsibilities for human and robot workers.
• Assign employees to monitor the Assembly robots and handle any errors or issues to minimize downtime. Employees should also perform regular maintenance on the robots to keep them functioning well.

With diligent planning and preparation, Assembly robots can be a highly effective addition to your factory, enabling substantial gains in productivity, quality, and profitability. By thoughtfully integrating them into your existing manufacturing processes, you'll be leveraging the power of automation to optimize your operations.

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Conclusion

Assembly robots offer tremendous opportunities to streamline operations, reduce costs, and improve quality in manufacturing. By implementing collaborative robots that work directly with human workers, you can boost productivity and morale. The initial investment in robotics may seem costly, but the long-term gains in efficiency and reliability will strengthen your business for years to come. Assembly robots are transforming factories around the world, and companies of all sizes are reaping the rewards.

The future is automated, and forward-thinking manufacturers are embracing robots to gain a competitive edge. If you want your company to thrive in the 21st century, now is the time to welcome your new mechanical colleagues to the assembly line. The age of human and robot collaboration is here.

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Next steps

Interested in bringing robotic assembly to your own business? RO1 by Standard Bots is the best choice for factories large and small:

1. Affordable: RO1 is the most affordable robotic arm in its class, starting at almost half the price of incumbent competitors. 
2. Powerful: RO1 is faster and more precise than competitors, despite having the highest payload capacity in its class at 18 kg.
3. Collaborative: RO1 comes equipped with safety sensors and built-in collision detection, for safe operation anywhere on your shop floor.

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Speak to our solutions team today to organize a free, 30-day onsite trial and get expert advice on everything you need to deploy your first robot.