THE INHERANT risk of human error, potential contamination and the demands of regulatory compliance place considerable pressure on packaging operations. Moreover, manual processes often struggle to maintain the precision, speed and consistency required to meet market demands.

To address the shortcomings of manual packaging in these sectors, Questt, a South American partner of global robotics supplier TM Robotics, has developed a market-first automated solution. Driven by the need for smarter, faster and more accurate vial packaging, Questt designed its QPack-1 robotic packaging machine as a complete solution.

Turnkey system

Questt’s QPack-1 machine uses both six and four-axis industrial robots to package vials using continuous movement and automatic feeding. This monobloc turnkey machine system integrates two robots in a single unit, each performing distinct tasks, and the machine has a small footprint, allowing it to be integrated even into smaller spaces.

Operators can program the machine to package a predefined number of vials into a custom thermoformed transparent plastic box. The first robot positions the box in the workspace, while the second transfers vials from the production line using a vacuum attachment to fill it. The first robot can insert a brochure before the box is closed and it moves to the next stage of the production line.

TM Robotics supplies the two robots used in the machine. Both are from Japanese robot manufacturer, Shibaura Machine, formerly known as Toshiba Machine. The first, a TVL700 six-axis robot, is lightweight and vertically articulated. With a reach of 700mm and a 4 kg payload, it offers exceptional versatility. In the Questt monobloc packaging machine, its speed and accuracy enable efficient box loading and unloading in the workspace. The second robot, a THL400 SCARA robot, has an arm length of 400mm and a payload capacity of up to 5 kg.

The Questt QPack-1 packaging machine addresses one of the most pressing drawbacks of the manual packaging processes – inconsistent and inefficient throughput. The machine was found to be able to package up to 7,200 vials in an hour. When the same process was carried out manually, workers packaged around 2000 vials in an average working day.

User-friendly interface

The QPack-1 also uses cutting-edge pneumatics from Festo and a highly intuitive Siemens programmable logic controller (PLC) to oversee packaging operations. It offers a user-friendly interface and touchscreen capability, enabling easy process adjustments and real-time performance monitoring. The PLC's simplicity streamlines programming, requiring minimal experience to operate the system. This is coupled with the machine's relatively straightforward installation and setup.

Equipped with sensors and cameras, the Siemens system identifies missing or misplaced products, or faults in the industrial robots. Upon recognising a fault, the system issues a warning and halts production until the operator addresses the issue with minimal downtime or further impact on production.

Production processes in life sciences, pharmaceuticals and veterinary manufacturing are also subject to stringent regulatory frameworks to ensure safety, efficacy and quality of all products. The QPack-1 is CE-certified, and additional validation can be conducted to meet required medical industry standards, including Installation Qualification (IQ), Operational Qualification (OQ) and Performance Qualification (PQ), ensuring that the machine operates as intended.

The limitations of manual packaging in the life sciences industries are evident, but the Questt QPack-1 robotic packaging machine effectively addresses the inefficiencies and inconsistencies associated with manual packaging.

www.tmrobotics.com

The Australia-based processing company supplies premium macadamias with a bespoke ‘key’ to crack the nut. Here’s how the business used robotics from Shibaura Machine to automate the picking-and-placing of keys into their macadamia nut packaging.

Freedom Fresh has long supplied its Happy Nut brand with a specially designed metal key. The macadamia nuts are cleverly roasted with a slit sawed into the shell, meaning customers can crack them open easily using the tool provided.

The challenge the business faced was automating the placement of the keys into bags during the filling process. The manual method was cumbersome and inefficient. It involving a worker standing on a ladder for prolonged periods of time and physically placing a key into each bag.

Shifting from manual to automated processing was a no brainer. The manual task was repetitive and posed obvious safety risks — that’s not to mention the monotonous nature of placing up to 20,000 keys into bags each day.

The goal of the automation project was clear: create a system that would both crack the problem of manual labour inefficiency and improve safety. The requirements included automatic pick and place of up to 60 keys per minute, seamless integration with the existing production line and a minimal factory floor footprint.  

Solutions from Shibaura Machine

To meet the requirements, the Freedom Fresh team enlisted automation experts, M.A.P Services, the authorised Australian distribution partner of TM Robotics and Shibaura Machine industrial robots.

The M.A.P Services team selected the THE400 robot as the foundation for the system. The THE series is a flagship SCARA robot range from Shibaura Machine — formerly known as Toshiba Machine until a corporate name change in 2020. The THE series is among the latest robotic launches from the Japanese manufacturer and an ideal choice for pick-and-place applications.

“The THE400 met all of the requirements for the Freedom Fresh project,” explained Nigel Smith, managing director and CEO of TM Robotics. “With a 400 mm arm length, the robot is relatively compact and requires minimal factory floor space. It boasts an impressive cycle time of 0.39 seconds with a 2 kg load and accurate movement trajectory with high-speed operation.”

The robot was equipped with the TS5000, a high-speed, precise robotic controller from Shibaura Machine. M.A.P also integrated an IFM O2D camera for vision processing and an IFM encoder for conveyor tracking, with SMC vacuum gear handling the pick-and-place mechanism.

An automated pick-and-place process

With this equipment now installed, the automated process begins with the IFM O2D camera monitoring a continuous stream of keys on the conveyor. Upon triggering, the camera captures an image and uses its in-built contour detection to locate each key. The camera then sends the position of each key to the robot controller via TCP/IP Ethernet communications.

“Integrating the vision system and encoder with the new generation TS5000 controller presented some initial teething issues,” explained Smith. “However, the user-friendly interface of the controller and the Shibaura Machine robot teach pendant made the integration process significantly easier. Our robot experts worked collaboratively with M.A.P Services to ensure seamless integration.”

The robot syncs with the IFM encoder for accurate conveyor tracking, picks up the key with a suction cup and carries it to the drop point. There, it waits for a signal from the nut-filling machine before releasing the key. This cycle repeats every second, ensuring a high-speed operation that leaves no room for error or delay.

Installation and results

The project exceeded all expectations. The automated system exceeded the cycle time requirement, achieving higher efficiency and reliability. In fact, Freedom Fresh Australia expressed immense satisfaction with the solution.

“Our experience with the new system has been an eleven out of ten,” explained Trevor Steinhardt of Freedom Fresh Australia. “The job of placing keys into bags was a difficult one, and there was no mechanical solution we could find. Now, the system just runs. It is coping very nicely and the strike rate is far better than a human operator.”

Joel Spiteri, the engineer from M.A.P Services that installed and commission the system added, “The first robot installation took place in July 2023, and it has performed flawlessly ever since. What’s more, the impressive results led Freedom Fresh Australia to order three more identical systems. Two of these robots are designed to work in tandem, further increasing cycle times and productivity. The additional robots were installed in early 2024 and are currently in the final stages of commissioning.”
 
When detailing the success of the project, Spiteri cited several factors. “First, the advanced technology of the Shibaura Machine SCOL, combined with the precision of the IFM O2D camera and encoder, which ensures accurate and rapid key placement. Second, the seamless integration of the THE400 SCARA robot with the conveyor tracking system and vision system to facilitate smooth operation.”

The collaboration between TM Robotics and M.A.P Services was also noted as instrumental to the project's success. Throughout the design, installation and commissioning stages, M.A.P Services and TM Robotics maintained a collaborative approach. Regular online meetings facilitated effective communication and problem-solving.
 
"Lastly, it was the customer-centric approach that delivered outstanding results,” added Spiteri. “We ensured that we understand and addressed the specific needs of Freedom Fresh Australia. This effort led to a tailored solution that has exceeded the customer’s expectations.”

Future prospects

Encouraged by the success of this project, Freedom Fresh Australia plans to further explore automation opportunities in its production processes. While automating processes like this one can be a tough nut to crack, leaning on the local expertise of M.A.P Services and the support of Shibaura Machine distributor, TM Robotics, for robot consultation can be the ‘key’ to achieving success.

www.tmrobotics.com

“MAMA, I'M coming home,” Ozzy Osbourne once sang, “here I come, but I ain't the same.” This could apply to manufacturers that are trying to quickly reshore production back to their own countries, under slogans such as “buy British” in the UK. In doing so, companies hope to mitigate supply chain issues caused by the after-effects of the COVID-19 pandemic, Brexit, the Ukraine conflict and material shortages.

But, to paraphrase Ozzy, manufacturing is no longer the same. Gone are the pre-Covid days when managers and suppliers could take supply chains for granted, and manufacturing was outsourced to countries like China at a significant profit. Instead, businesses are under pressure to reshore their production while keeping it economically viable, reducing lead times and improving quality of service, despite the supply chain disruptions.

However, according to the London School of Economics, robotisation might play a vital role in helping manufacturers bring their operations back home to the UK.

High production

Take injection moulding for instance, a manufacturing process that Digital Journal predicts will see booming growth between 2023 and 2030. Injection moulding is used to manufacture a huge variety of plastic parts – everything from medical devices to takeaway food containers – with good repeatability, consistently high production with low waste, and a low-cost-per-part. However, the injection moulding process can be expensive, overall. Estimates range from £3,000 to £100,000, relative to the size of the product, the volume of manufacture and the speed of production.

How can automation and robotics lower these costs? First, let’s consider that 90% of the costs of injection moulding are attributable to the electricity used to power the injection moulding machine itself. Machines powered by a hydraulic motor are often favoured because they produce higher energy levels and higher injection pressures, and the initial cost of the machine is lower.

But, there are disadvantages. The machine’s hydraulic power is connected to an electric power unit, so works at maximum capacity during the entire moulding process and even consumes energy when idle. These factors significantly impede the energy efficiency, and are why manufacturers should instead consider all-electric machines.

Energy efficiency savings

Let’s examine the case of Lotan, a TM Robotics customer and manufacturer of plastic containers. The UK-based company relies on Shibaura Machine’s all-electric injection moulding machines (IMM) supplied by TM Robotics. Performance benefits of the IMM include a range of clamping force from 50 to 2,500 tons, which can be calibrated by a digital direct screw transfer (DST) control for added production flexibility. While all-electric machines are initially more expensive with lower injection pressures, they greatly outperform hydraulic versions in a variety of other ways.

Advantages of all-electric IMMS include higher rates and speeds of injection, because they rely on toggle clamping rather than direct pressure clamping, which is better for high-speed injection moulding. Other benefits are improved dry cycle times and the overall stability of the mould itself.

But what about the energy savings? Performance tests by Shibaura Machine measured its EC650SX-61B IMM, with a clamping force of 650 tons, against a hydraulic servo machine. It delivered a 51% energy reduction. Another EC-SX model, the 1800t EC1800SX-155B, was tested against a competing all-electric IMM. Although both machines had the same energy consumption, the Shibaura Machine IMM delivered a faster cycle time, for overall energy efficiency savings of 30%.

Bringing it all back home

Meanwhile, Lotan has experienced 20 to 40% lower running costs and 35% faster cycle times with the all-electric IMMs, plus a lower cost-per-mould.
Thanks to these benefits, Lotan has ordered several more Shibaura Machine IMMs from TM Robotics, specifically its newest SXIII range of injection moulding machines. An additional benefit is that the SXIII can be easily integrated with Shibaura Machine robots like the TVL industrial robot range that are compact, lightweight and space saving. Each robot has varying reach and payload specifications, and a longer arm length compared with previous robot ranges.

The advantages of all-electric injection moulding machines, like the EC-SX and SXIII, demonstrate how automation and robots can help manufacturers bring their operations back home to the UK. Reshoring can be achieved with cost- and energy-efficiency as well as productivity benefits – even if, as Ozzy sang, things “ain't the same."

www.tmrobotics.com

The Journal of Clean Production’s findings are wake-up call to manufacturers, particularly as demand for injection moulding processes continue to grow. For example, the market for injection moulded medical devices plastics is expected to see booming growth between 2023 and 2030.

Injection moulding is used to manufacture a huge variety of parts, and has several advantages. They include the ability to mould a wide variety of plastics, good repeatability, consistently high production with low waste and a low-cost-per-part — the latter is always a priority.

Maintaining a low cost-per-part throughout the manufacturing process is vital for reducing costs and delivering a higher product value — from both the manufacturer’s and the customer’s perspective. While injection moulding can support this, manufacturers are also concerned about the energy costs of injection moulding, and how this effects sustainability and the bottom line.

More than 90% of the costs of injection moulding can be attributed to energy use. This mainly applies to the electricity used to power and operate the injection moulding machine. As a result, there has been some debate in industry about the cost and sustainability advantages of hydraulic injection moulding versus all-electric machines.

Injection moulding machines powered by a hydraulic motor can produce higher energy levels and higher injection pressures, and the initial cost of the machine is lower. But there are also disadvantages with hydraulic machines. They include the machine’s high consumption of electric energy, because its hydraulic power is connected to an electric power unit that works at maximum capacity during every phase of the moulding process.

Whole-life cost

Although hydraulic injection moulding machines are less expensive initially, it’s important to consider the whole life cost when buying new machines. This was demonstrated by TM Robotics’ customer Lotan, a manufacturer of plastic containers based in Leicestershire, UK. All of the injection moulding machines in Lotan’s production facility are electric, rather than hydraulic.

The company relies on Shibaura Machine’s all-electric injection moulding machines (IMM) supplied by TM Robotics. The machine is manufactured in-house by Shibaura Machine, formerly known as Toshiba Machine. Performance benefits of the IMM include a range of clamping force from 50 to 2,500 tons, which can be calibrated by a digital direct screw transfer (DST) control for added production flexibility.

Although all-electric machines are initially more expensive with lower injection pressures, they are shown to outperform hydraulic versions in a variety of other ways. Advantages include higher rates and speeds of injection because the all-electric maching relies on toggle clamping rather than direct pressure clamping, which is better for high-speed injection moulding.

Further advantages include improved dry cycle times and the overall stability of the mould itself. Thanks to these benefits, Lotan has ordered several more Shibaura Machine IMMs from TM Robotics, specifically its newest SXIII range of injection moulding machines. The SXIII is an enhanced performance model that provides significantly faster injection speeds than traditional moulding equipment. As a result, the machine offers a 35 per cent faster cycle time than conventional hydraulic servo IMMs. Lotan also achieved a lower cost-per-mould.

The bottom line

Aside from performance advantages, injection moulding machines must also be easy to use. This guarantees Lotan’s team can stay on-track to meet their key performance indicators (KPIs) by controlling the equipment and keeping it running sustainably. That’s why SXIII range of injection moulding machines are equipped with Shibaura Machine’s user-friendly controller that connects to Lotan’s programmable logic controller (PLC) for simple, repeatable operations.

All-electric moulding machines also have the edge when it comes to maintenance. With PLC controllability, injection moulding operations can be tie-into the production facilties Internet of Things (IoT) things systems. Data on the IMM’s performance can be collected through sensors and relaid to the plant’s enterprise resource planning (ERP) or manufacturing execution systems (MES) to support preventive maintance, traceability and quality management.

But, what what about the energy efficiency of all-electric versions hydraulically-powered machines? By using Shibaura Machine’s all-electric IMMs, Lotan has experienced 20 to 40% lower running costs compared with older-fashioned hydraulic machine. Traditional hydraulic injection moulding machines are also less efficient because they consume energy even while idle, whereas all-electric injecting machines only use energy while in action.

Indeed, Shibaura Machine’s all-electric IMMs have been found to yield energy savings of 60 per cent compared with European hydraulic servo IMMs. Other performance tests by Shibaura Machine measured its EC650SX-61B IMM, with a clamping force of 650 tons, against a hydraulic servo machine. It delivered a 51% energy reduction.

In another instance, another EC-SX model, the 1,800 ton EC1800SX-155B, was tested against a competing all-electric IMM. Although both machines had the same energy consumption, the Shibaura Machine IMM delivered a faster cycle time, which gave overall energy efficiency savings of 30%.

Injection moulding might presently be responsible of up to 90 per cent of the processes GWP. Hower, the performance of all-electric IMMs like Shibaura Machine’s  SXIII and EC-SX show this trend can be reversed, with positive effects on sustainability and also manufacturers’ bottom line.

Dervish Ibrahim is international sales manager at TM Robotics

www.tmrobotics.com

Taking place at the NEC in Birmingham from September 26 to 28, Interplas is the first UK trade fair for Shibaura Machine since UK distributor, TM Robotics, agreed an exclusive distribution partnership with the manufacturer last year. TM Robotics now handles all industrial robot and injection moulding distribution for Shibaura Machine in the UK and Ireland.

TM Robotics has long been a prominent distributor in industrial robotics and automation and has been supplying Shibaura Machine robots to the market for over two decades. At Interplas 2023, TM Robotics will launch its new product offering from the Japanese manufacturer — the full all electric injection moulding machine range, plus service and maintenance.  

Interplas 2023 presents an excellent opportunity for TM Robotics to introduce this offering to the market and meet with potential customers in the plastic parts manufacturing sector. From stand H41, the TM Robotics team will be available to discuss the full range of technologies from Shibaura Machine, including injection moulding machines, industrial robots and integrated solutions that use both technologies.

“The new offering includes the all-electric SXIII injection moulding machine series from Shibaura Machine,” explained Nigel Smith, managing director of TM Robotics. “The range of machines feature enhanced versatility and performance and streamlined design, providing significantly faster injection speeds than traditional moulding equipment. The series is available in 17 different injection capacities and dimensions and can be used for virtually any moulding application.”
 
In addition to the supply of the all-electric series, TM Robotics can also obtain parts and perform maintenance for hydraulic Shibaura Machine equipment — and legacy Toshiba Machine-branded moulding equipment that is still in operation in the field.  

“Our strength is in our ability to integrate injection moulding machines and robots from Shibaura Machine — we are the absolute experts in this technology for the UK and Ireland,” continued Smith. “We encourage those interested in automated solutions for injection moulding to arrange a meeting with our experts at Interplas. The team has impressive knowledge of Shibaura Machine technologies, and we have recently expanded the team with two new injection moulding experts to further support this sales area.”

Peter Coltman and Jakub Urbanek joined the TM Robotics team as injection moulding machine service manager and technical support, last year. Having worked exclusively with Shibaura Machine’s injection moulding equipment since 2018, the engineers can provide expert consultation and advice on any injection moulding query.

Interplas follows a significant new robot launch for TM Robotics. The organisation launched its THE SCARA series for the European market at the Automatica trade fair held in Germany in June 2023. The launch saw TM Robotics introduce two new larger robots to the existing series.

“The THE800 and THE1000 robots are newly available in Europe,” continued Smith. “The THE series is widely recognised as the price-to-performance leader in SCARA robots and is ideal for pick-and-place applications. Alongside these models are a number of six-axis robot options, many of which are compatible with the Shibaura Machine injection moulding machines for loading and unloading. At Interplas 2023, we will have a video demonstrating this robot integration.”

TM Robotics invites attendees of Interplas 2023 to visit the Shibaura Machine stand H12 to discuss the range of Shibaura Machine injection moulding machines and complementary robots.

www.tmrobotics.com

ANY EQUIPMENT with a robotic element requires integration of automated technology. For instance, incorporating a traditional robot arm onto a pick-and-place machine or adding automated movement onto otherwise static industrial equipment.

Robotic supplier and Shibaura Machine distributor, TM Robotics, works alongside machine builders to help them choose the correct robot for their application and understands the intricacies that OEMs need to consider.

Flexibility

OEMs often require more flexibility than an off-the-shelf robot can deliver. At TM robotics, we partner with machine builders to create new robot variations to meet their unique needs. Grabit, a company specialising in electro-static adhesion solutions for material handling, is a good example of this.

Grabit was developing a machine to automate the materials handling process to assemble the upper of shoes. Intrigued by Shibaura Machine’s SCARA robot range, Grabit turned to TM Robotics for support.

To meet Grabit’s unique requirements, the Shibaura Machine engineering team in Japan re-structured some of the THL1000 SCARA robot key features.  Due to the size of the gripper Grabit planned to use, the Japanese engineers maximised the speed, minimised the cycle time and stopped vibration with some fine tuning of hardware and software.

“TM Robotics support and customisation process were not limited to phone calls and e-mails,” explained Harsha Prahlad, co-founder and chief technology and products officer at Grabit. “They were able to talk to us in a language that our technical team understands and allowed us to fine-tune the machine to our exact requirements, not many robot companies allow for that level of personalisation.”

When choosing a robot supplier, determining the level of customisation they can deliver is essential. For OEMs with complex machinery or unusual applications, embarking on future iterations and modifications to meet customisation needs could prove to be much more costly.

Robot choice

For customers that aren’t well-versed in robot terminology, choosing the correct machine can be daunting. SCARA, six-axis and Cartesian are the three most common industrial robots’ types and offer a good place to start for those new to robotic technology.

Selective Compliance Articulated Robot Arms – otherwise known as SCARA robots – are designed to mimic the action of a human arm, albeit a slightly rigid one. SCARA robots can automate assembly or loading and unloading tasks with speed and precision by offering fast motion in the X and Y axis. These robots are ideal for applications requiring fast and repeatable movements, like electronics assembly. 

Six-axis robots offer more flexibility. Typically, these robots are mounted on a pedestal and offer the most directional movement. The robot arm can move in the X, Y and Z planes as well as positioning itself using roll, pitch, and yaw movements.

Cartesian robots use a one-dimensional motion to boost high reliability. Using between three and four sliding joins, Cartesian robots are suitable for fast parts assembly, conveying and transfer applications. Focusing on providing ease of operation, TM Robotics’ range of Cartesian models also requires little-to-no programming. Sometimes, however, an off-the-shelf robot will suffice.

“Shibaura Machine have a full range of Cartesian, SCARA and 6 axis robots which are ideal for our various requirements involved in the different soldering machines,” explains Albin Müller, managing director of ELMOTEC, a user of TM Robotics’ robots for its range of soldering machines.

"The ease of programming is a huge benefit and the flexibility of product in terms of reach and payload mean that we can select the right robot for the project in terms of specification and price.”

Software control

Having an industrial robot that can provide software control can increase productivity and safety to your machinery, especially in precise and repetitive operations. CASI, a specialist machine builder of automated machinery, partnered with TM Robotics to create the Intelligent Box Opening Device (IBOD).

TM Robotics customised the internal parameter and PLC settings to enable the robot to cut boxes efficiently. Utilising this built-in intelligence, IBOD takes readings from photo optics and linear displacement sensors to measure the dimensions of each box before positioning it for cutting.

Software-controlled automation lets IBOD cut boxes according to bespoke specifications. This also helps the robot to avoiding damages when finding obstruction in the cutting process, such as metal staples or tape.

“We chose the Shibaura Machine TH1050A SCARA for our IBOD and box cutting projects as it is arguably the strongest, and one of the most rigid arms on the market,” explains Jeff Grindstaff, product manager at CASI. “The support from the engineering team has been excellent as we have been able to custom build algorithms in the Shibaura Machine internal PLC, which is built into as standard with the SCARA controller to monitor torque settings when cutting the box.

“With this additional function we have been able to not worry about damage to the robot when cutting difficult cardboard.”

Training 

Machine builders and OEMs can also benefit from training from their robot supplier. Thorough training can ensure that robot programming and control is simple – and the OEM isn’t left with a robotic machine that they aren’t able to program correctly. It is paramount to ensure the supplier has delivered a compressive training process and, where possible, can pass this technical support onto the OEMs end users.

ASG, a certified manufacturer, provider for automated solutions worked alongside TM Robotics to develop robotic screw feeding solutions. “The robustness of the robot’s arms was one of the key points in choosing TM Robotics, as we have a unique geometry with end of arm tooling,” said Bryon Shafer, general manager of ASG Jergens.

“Because of this specification we wanted a company that could be on hand to answer any questions that we had, TM Robotics not only delivered with their products, but also with their stellar customer service.

“By having a person on hand to answer questions and walk partners and customers through their installation, issues get solved in a timely manner.”

TM Robotics training courses are delivered in person or remotely by professional robot engineers, who provide a wealth of experience and expertise in Shibaura Machine’s automation products.

As robotic adoption continues to grow — choice, flexibility, and versatility from robot suppliers is highly sought after.

Nigel Smith is managing director of TM Robotics

www.tmrobotics.com

Toshiba Machine has been an established producer of high-quality industrial robots for over two decades. The newly announced collaborative robots, encompassing a humanoid and SCARA version, are the first machines of their kind from the Japanese manufacturer. Toshiba Machine has previously prioritised the manufacture of industrial robot models such as six-axis, SCARA and Cartesian.

Toshiba Machine’s humanoid cobot was demonstrated at IREX in a live parts assembly demonstration. Boasting a 6kg maximum payload for each arm or 10kg when used in combination, the humanoid cobot has been developed to meet demand for human-machine collaboration in parts assembly and inspection processes.  

The SCARA model, which is also collaborative, expands on Toshiba Machine’s established expertise in manufacturing traditional SCARA robots. At IREX, the SCARA display demonstrated how a cobot can be used in delicate electronics handling and packaging applications — a task usually limited to highly accurate industrial machines. Also featuring two arms, the SCARA robot is suited to fast-paced handling applications.

As collaborative robots, both models will be deployable alongside human workers, allowing manufacturers to benefit from a combination of automated and manual processes. The cobots will be available with brand new, state-of-the-art robotic vision systems.

IREX 2019 also hosted the Japanese launch of Toshiba Machine’s THE600 SCARA robot. The THE600 builds on the specifications of the existing THE400 SCARA robot, boasting twice the speed and 60 per cent higher payload capacity than competing SCARA models in the same price range. Visitors to IREX can witness a demonstration of the THE600 being driven by the new TS5000 controller, a new product from Toshiba Machine which will also be available to purchase in 2020.

“Toshiba Machine has been carefully developing its new collaborative machines for several years,” explained Nigel Smith, managing director of TM Robotics. “IREX provides an ideal opportunity to showcase the impressive engineering behind these two models — as well as providing visitors with live demonstrations of how these machines operate. Our collaborative offering has been a long time coming, but it’s certainly worth the wait.”
 
The new robot launches mark the beginning of a new era for Toshiba Machine and its industrial robot division. From April 1, 2020, the company will return to its original name of Shibaura Machine. The name change represents a formal separation from Toshiba Corporation, but will have no impact on the new product releases that have been developed at the company’s Japanese base.

“The corporate name change will have no bearing on TM Robotics and our global distributor network, nor will it change the outstanding quality of the industrial robots —and now collaborative machines — that we offer at TM Robotics,” concluded Smith.

Returning to its original name — the company was initially founded as Shibaura Machine Tool Co. in 1938 — Toshiba Machine’s name change will reflect its formal separation from the larger Toshiba Corporation in 2017.

While Toshiba Machine may be moving away from the name from 1st April 2020, the company aims for a seamless transition with no impact to business, customers or shareholders.

“To continue our evolution, our company will change its name to Shibaura Machine, and focus on providing customers with greater flexibility and responsiveness,” explained Takahiro Mikami, president of Toshiba Machine. “We look forward to continuing our growth and industry-leading contributions to the markets we serve in the future. Even though the name is changing, our commitment remains the same. Our goal as Shibaura Machine is to be a supplier of the highest quality machinery and systems, one that is well-positioned to grow and contribute to the global economy for decades to come.”

“From April 2020, TM Robotics will become the official distributor of Shibaura Machine robots,” continued Nigel Smith, managing director of TM Robotics. “The corporate name change will have no bearing on TM Robotics and our global distributor network, nor will it change the outstanding quality of the industrial solutions we offer — same robots, new name.

“TM Robotics customers can be assured that the quality of the robots we distribute will continue to be of the very highest that they are accustomed to. The same expert Japanese engineering will be present in every robot we supply.”
 

Using a rotating disk actuated by a servomotor, the Flexibowl provides an effective method of sorting and separating small parts for production. This is used in combination with a Toshiba Machine SCARA robot, the THL700.

The THL series is a collection of nine low energy SCARA robots from Toshiba Machine. Spanning from 300mm to 1200mm arm’s length, the vast THL range can provide a suitably sized machine for every robotic application. The THL700, the mid-sized model, boasts a 700mm arm’s length with a 10kg maximum payload and a cycle time of 0.50 seconds when operated with a 2kg load. Stand E20

According to the International Federation of Robotics (IFR), Europe is the second largest market for industrial robot sales. Purchasing 56,000 units in total in 2017, Europe reached a new peak for robot sales for the third year in a row. That said, much of this deployment was attributed to Germany, so where does this leave us Brits?

Initiatives for digitalisation

Britain is no stranger to the Fourth Industrial Revolution, Industry 4.0 or whatever you wish to call today’s changes in manufacturing. In October 2017, the British Government announced its first major initiative to improve digitalisation in manufacturing, the Made Smarter review.

Made Smarter called to boost productivity by encouraging manufacturers to embrace industrial digitalisation technologies (IDTs) — which includes robotics, automation and intelligent control software. The review suggested that a greater uptake of these technologies could create 175,000 new jobs in the next decade, because of a 25 per cent productivity boost in the sector.

Efforts of the Made Smarter review were bolstered in January 2018, when the World Economic Forum (WEF) in Davos released its first ‘Readiness for the Future of Production Report’. The report outlined how well-positioned economies are to benefit from Industry 4.0 technologies. The United Kingdom claimed a space in the top 25.

However, six months later in June 2018, the initial findings of the IFR’s World Robotics Report 2018 suggest that as it currently stands, the same nations are still leading robot sales. Germany has remained Europe’s forerunner with a total of 22,000 robot units sold. To put that into perspective, that represents over a third of Europe’s total robot purchases.

Much of this success may be due to Germany’s booming automotive industry, where manufacturers have long used six-axis robots in their production. Looking to the future, increasing the volume of robot deployment in Britain will rely on tapping into new markets by introducing small to medium-sized companies to automation.

Simplified programming

To reach this market, industrial robots must become more accessible, in relation to both cost and user experience. According to TM Robotics’ Global Robotics Report 2018, simple programming was one of the most important features for end-users when choosing a robot. In fact, 79 per cent of respondents named this as a top five consideration.

Currently, there are over 1500 different programming languages in the world. Even for the most proficient robot engineer, learning every potential robot programming language is an impossible and impractical task. For new automation users, such as the small to medium-sized market, this can be incredibly daunting.

BASIC and Pascal are the basis of several industrial robot languages and tend to be the first any budding robot programmer begins to learn. BASIC, standing for Beginners All-Purpose Symbolic Instruction Code, is relatively simple, but can also be considered outdated for today’s demanding robotic applications.

Simple programming may be a top priority, but today’s end users also don’t want to compromise on robot ability — particularly for their first robotic investment. Therefore, a balance needs to be struck. Toshiba Machine’s controllers, for example, are programmed in SCOL. This is a programming language that is similar to BASIC, but with more advanced features.

In fact, Toshiba Machine’s latest robot programming software, TSAssist, has been designed around usability. By opting for intuitive screen design and customisable operator panels, beginners find it easy to understand. TSAssist is compatible with any of TM Robotics’ industrial robots, including the extensive SCARA, Cartesian and six-axis ranges.

To cobot, or not

Growing demand for easily programmable robots is also evident in the rapid increase in sales of collaborative models — robots that can work without protective barriers between machine and employee. Collaborative robots, or cobots, currently account for 3 per cent of the total robotics market, but this figure is expected to reach 34 per cent by 2025.

These machines have been marketed as easy to program, but despite this, they should not be considered as a total alternative to traditional industrial robots. While cobots do boast some impressive responsive features, these machines generally cannot tackle the dangerous, repetitive and heavy-duty tasks usually associated with industrial robots — and this is something that new automation users aren’t always aware of.

In fact, 55 per cent of respondents to the Global Robotics Report do not believe that cobot technology is advanced enough to deliver the performance required for manufacturing, and a further 25 per cent were unsure of their capabilities.

To encourage investment from small and medium-sized businesses, robot manufacturers must ensure their machines are easy to program and don’t intimidate potential automation users. What’s more, unlike the large-scale automotive manufacturers of Germany, Britain’s robot customers may require more consultation and guidance to choose which robot is right for them — a cobot, or not.

The IFR predicts that the world will experience a further robotics boom in 2019, with an estimated 2.6 million robot units set to be deployed. Regardless of the initiatives and investments in place to encourage Britain to embrace robotics, efforts must begin with robotics manufacturers themselves. Simplified robot programming is key.