Switching to Robotics

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p r e s e n t s
Switching to Robotics
FRP and Polyurethane Applications

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Switching to Robotics
Why Automate?
The constantly increasing cost of doing
business Increasing material costs Increasing
labor costs
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Switching to Robotics
Why Automate?
ALL of These Issues Increase the Cost Per Part
Produced
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Switching to Robotics
Why Automate?
Environmental and exposure regulations are
driving manufactures to investigate alternative
methods of material application. Consider the
following video Stronger environmental
emission regulations drove this customer to
automate their manufacturing process. The
result is a more competitive manufacturer that
also reduced emissions.
Please Click on Video 1
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Benefits Of Robots
Material Savings Repeatable robot paths and gun
triggering means the material application will be
repeatable and consistent
Please Click on Video 2
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Material Savings - Case Study
Whirlpool and Spa Manufacturer
Before After Total Material Total
Material Overspray Chop Chop On Part
Usage Quantity Percent Shell 1
38 83 45 47.2 2.2
4.6 Shell 2 38 82.5 44.5
47.1 2.6 5.5 Shell 3 38
83.0 45 46.9 1.9
4.0
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Switching to Robotics
Without Robot
Typical weight variance graph- pull weight / part
weight each point represents one job- all
measurements in relationship to ideal nominal
weight
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1.5
-1.5
-10
With Robot
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Switching to Robotics
Benefits Of Robots
Product Quality Automated robotic application of
material brings consistency to the spray out
process. Most advanced robotics systems include
fluid delivery monitoring which alert plant
personnel when material delivery is out of a
desired tolerance.
Please Click on Video 3
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Switching to Robotics
Benefits Of Robots
Proper application of material requires
consistent material delivery, consistent gun
triggering and maintaining a consistent gun
target distance. Robots provide all of these
requirements Additionally, proper application of
these materials eliminates product cracking, part
re-work due to appearance concerns and fiber
bleed through. These problems directly affect
warranty costs, which also affect the bottom
line. Robotic application of materials can help
the end user get these product variables under
control, reducing long term warranty concerns.
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Switching to Robotics
Benefits Of Robots
Labor and Environmental Considerations Manual
spray out of the FRP process requires an employer
to provide equipment for an employee to work
within a hazardous environment. Robots can
easily work within a hazardous environment this
allows the employer to limit the exposure direct
labor has with airborne chop emissions. With
removal of humans from the actual spray
environment, booth air can be recirculated, and
airborne concentrations within the booth can
remain at a higher level releasing less emissions
in the air. This might allow the end user to add
a rotary concentrator to further reduce emissions.
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How It Works
Please Click on Video 4
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Customer and Supplier Requirements
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Customer / Supplier Requirements
Customer Requirements One Dedicated
Robot Operator Per Shift Optimal operator has
knowledge of Fiberglass Chop Polyurethane
Applications (fluid delivery equipment, mold
variations,etc.) Operator will learn robot
programming error recovery
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Customer / Supplier Requirements
Customer Requirements All robot operators
should attend an Operations and Programming
Class offered by robot supplier Dedicated
project manager for system start-up
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Customer / Supplier Requirements
Supplier Requirements System supplier should
have extensiveknowledge of robotic Fiberglass
Chop and Polyurethane applications Experienced
personnel in ProjectManagement, Installation,
and Engineering Product and software packages
dedicated tospecific markets (RD) Established
market base
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Conclusion
Robotic automation can reduce material usage and
improve part quality. Robots can remove personnel
from hazardous locations and also increases
material application consistency. Robots can help
a manufacturer reduce employee exposure to
styrene emissions. Robots can improve product
manufacturing process.