RBCobots set to help satisfy the danish food demand at FKI | Uniwelco
The next time you bite into a hot dog from a Danish gas station, it has very likely been made on a FKI grill which was made by a robot.
At Flexi Metal in Vildbjerg the workers already have tried to work alongside a welding robot in the production. Though ...
At Flexi Metal in Vildbjerg the workers already have tried to work alongside a welding robot in the production. Though the old robot was a bit bigger than the collaborative robot, which has arrived today. In the same spot, where the old robot stood, the new RBCobot will stand. Because of the new addition, we have visited them; the robot is going to be installed and the welders will learn how to operate it.
Jes Peter, who is our mechanical and software developer and is a part of the robotics development in Svejsehuset, is busy setting up the robot, as I arrive. He has already tried to capture the curiosity of the to welders Lasse and Karsten, even though they have to wait a little bit longer to test drive the robot. This is because the robot has to be checked after transport, as well as ensuring that the table used for the robot is completely level. This is due to the fact, that the table will serve as a coordinate system, and the best results are achieved by having a level table.
"RBCobot-rules"
When everything is sorted, the robot is now ready to let the welders familiarize themselves with it. Jes Peter changes the mode, and the hands that previously cared for the robot, are now extended along side his body; he is done touching the robot. He explains, that it is a technique he always uses, during the initial training.
"I usually do everything in my power not to touch the robot, when I hand it over and the welders have to learn how to use it. It was difficult for me in the beginning, because I know what buttons to press. But I usually just get them started immediately. This way they learn much more."
And it seems to work: almost automatically Lasse moves to the control panel, while Karsten repositions the robot arm. They are now ready to get to know their new colleague.
Jes Peter guides them in the back and occasionally writes an important sentence or a practical tip on the whiteboard, which is mounted behind the robot. With the title "RBCobot-rules" the whiteboard will remain hanging, until the next vist, where he once again will meet the team and the robot.
Monotonous work and large batches
According to Lasse from Flexi Metal purpose was to make welding seams, that are so flat, that sanding them down would become unnecessary. This is done, amongst other things, to reduce the workload of the "guy" Lasse refers to as "the robot next door". On the other side of room separator Poul is sanding down objects.
"He hasn't done anything else for the three years, that he has been here. It's very monotonous work."
It is exactly the monotonous work, that the robot is supposed to take over and according to owner Simon Agergaard, Flexi Metal has been looking for a collaborative welding robot for the last year. The answer was an RBCobot after a thorough test of the objects, which the robot will weld. It is exactly this line of work, that has seen an such an increase in demand, whereas it warrants a new robot again:
"It has now been 2,5 years, since we got rid of the old one. We sold the robot back then, because we didn't need a robot anymore. Now we have purchased one again. We had so many items, which we do continuously - it is the batch size which has increased significantly. As you can see behind you, there is plenty of work to do."
Simon Agergaard points to the many pallets with items. They will be transformed to manhole covers - the premium type, which you can cover with grass or tile - and the amount is significant. In other words, the robot has its work cut out for it. After lunch this exactly what happens. The welders have been practicing the entire morning on some items, that Jes Peter brought with him, and the time has come to put the real items on the table.
Karsten mounts the items on the welding table
The table holds four items in total. Every item is fixed in the same position in clamps every time and the welders can run the program again and again.
Two weeks later
Two weeks after the visit we call the co-owner Jan Andersen, to hear how the first period with the robot has been.
"It's been great. It has been running almost ever since. Under all circumstances it operates for 8 hours a day."
The welders are also quite satisfied with the robot - even though they don't necessarily find it super easy. This is why Jan is quite pleased, that they are two people on the robot, so that they can assist each other in the beginning. He also happy about the continuous contact that he and the welders have had with Jes Peter.
"Just the fact that they can call, when they have a question, they can get it cleared up over the phone - it's quite lovely having the assistance available. It's important when you believe that you've understood all the information given on the training day and it turns out, that you haven't necessarily understood it anyway."