Robotic Mixing Solution Automates
Critical Aqueous Mixing Process for Client
INTRODUCTION
TURNING A MANUAL MIXING STEP INTO A FULLY AUTOMATED PROCESS
Cleveland Automation Systems® (CAS) was approached by a client facing a significant bottleneck in their production process—an aqueous solution mixing operation that required frequent manual intervention.
The solution needed constant agitation to prevent particles from settling, but this manual requirement was the only aspect preventing full automation. The client’s process allowed the machine to run for several hours without human intervention, except for this manual mixing, which was becoming a significant inefficiency.
The Challenges of Manual Aqueous Mixing
The client’s production process required an aqueous solution to be constantly mixed manually, which meant increased labor costs, operational inefficiencies, and risk of errors, potentially impacting the product’s quality and overall production output.
This labor-intensive process created bottlenecks, requiring operators to frequently intervene and manually stir the solution, leading to inefficiencies. If unresolved, these issues could lead to unnecessary downtime and reduced profitability. Failure to keep this compound suspended in solution could cause product defects and quality issues for the customer.
Failure to automate this could lead to continued inefficiency, increased operational costs, and lower product consistency—ultimately risking the company’s competitive advantage.
Solution: Automated Robotic Mixing System
To address the challenges, CAS conducted a thorough site assessment and identified that a Robotic Mixing Solution was needed to automate the mixing process of the aqueous solution while ensuring consistency. The solution would mimic human mixing with the same accuracy and consistency, while also enabling seamless integration into the existing system without compromising production capabilities. The primary objectives were to fully automate the mixing operation, eliminate the need for operator intervention, and enhance production efficiency.
Upgrading to a Robotic Mixing Solution
CAS’s engineering team designed a robotic arm to perform the mixing task automatically at pre-defined intervals. The Robotic Mixing Solution involved integrating a Universal Robots UR3 robotic arm into the existing setup to perform the agitation, replicating the human process with far greater precision and consistency.
The key objective was to achieve a mixing solution that operates automatically during machine auto-mode without relying on manual labor. This required both mechanical design precision and the seamless integration of electrical components into the current production line.
Human-Machine Interface (HMI) Integration
CAS included an intuitive HMI to enhance the automation further, allowing operators to monitor and manage the robot’s mixing activity in real-time. The HMI provided a visual interface for adjusting cycles, monitoring mix consistency, and ensuring optimal performance—giving the operator more control over the mixing process and ensuring high-quality results.
Seamless Integration with Existing Machinery
The solution also involved retrofitting the robotic system onto the existing equipment. This required precise modifications to ensure that the Robotic Mixing Solution was integrated efficiently without causing interruptions to ongoing production. The system was programmed to start mixing at a pre-defined cycle count, ensuring the solution remained homogenous throughout production.
System Requirements Overview for Robotic Mixing Solution
To create an effective automation system, the project focused on the following critical requirements:
- Automatic Operation During Auto Mode: The solution needed to run automatically alongside the existing equipment during its full auto mode, ensuring minimal operator intervention.
Replication of Human Mixing: The robotic arm had to mimic the manual mixing motion precisely, ensuring the particles in the solution remained suspended consistently, much like when manually mixed by an operator.
Hardware Used in Robotic Mixing Solution
Universal Robots UR3
The Universal Robots UR3 robotic arm was selected for this project due to its compact design and high precision. This collaborative robot could seamlessly integrate with the existing equipment, offering both safety and ease of programming. It provided the agility needed to mimic manual mixing and handled the task with repeatable accuracy. Learn more about Universal Robots UR3.
Robotiq Force Copilot Software
Robotiq Force Copilot was employed to give the robot enhanced control over force and movement, allowing it to mimic the tactile feedback typically provided by human operators. This software helped ensure that the mixing action remained consistent throughout the production cycle, which was crucial for keeping the solution homogenous. Learn more about Robotiq Force Copilot.
Software for Robotic Mixing Solution
- Data Acquisition: CAS utilized sensors to collect data on the viscosity and consistency of the solution. These sensors were directly integrated with the robot’s control system to ensure optimal mixing intensity.
- Data Processing: Real-time processing capabilities were developed to analyze the collected data, triggering adjustments to the mixing cycle if necessary.
- Data Storage: A secure and scalable cloud-based data storage solution ensures the reliability and accessibility of historical mixing data.
- Web Application: The HMI integrated a web application that allowed operators to visualize production metrics, adjust cycles, and interact with mixing parameters remotely.
Outcomes and Benefits of the Robotic Mixing Solution
The Robotic Mixing Solution enabled the client to automate the previously labor-intensive mixing operation, resulting in significant improvements:
- Increased Productivity: The solution allowed the machine to operate independently, increasing overall uptime and productivity. Operator labor for mixing was eliminated, saving around 8 hours per week.
- Improved Product Consistency: Automating the mixing process ensured that the aqueous solution was thoroughly mixed at the correct intervals, resulting in better product consistency and quality.
- Reduced Downtime: By removing manual intervention, production could continue seamlessly, reducing the likelihood of downtime caused by human error or delays.
- Future Scalability: The client can now expand their operations with this automated system. The solution is adaptable to additional equipment, future upgrades, or production expansions.
- Quality and Compliance: This system allowed for improved and consistent product quality, reducing the risk of defective products and potential returns.
Customer Benefits from Robotic Mixing Solution
The client reported numerous benefits as a direct result of the implementation:
- Enhanced Consistency and Quality: By automating the mixing, they eliminated inconsistencies caused by manual intervention, improving overall product quality.
- Reduced Operational Costs: Labor previously allocated to mixing was redirected to other critical areas, reducing overall operational costs.
- Higher Production Efficiency: The ability to run the entire system in auto mode increased production efficiency, allowing the company to meet higher production demands.
Technologies Used
- Universal Robots UR3: Agile and compact, ideal for precision tasks in automation.
- Robotiq Force Copilot: Added force control, enabling the robotic arm to emulate human dexterity.
- Onlogic Panel PC: Used to integrate the HMI for easy system control and monitoring.
- Cloud-Based Data Storage: Secure storage for data analytics and historical production performance.
Optimize Your Production Processes with CAS’s Robotic Mixing Solutions
This case study highlights how Cleveland Automation Systems effectively implemented a Robotic Mixing Solution, automating a previously manual operation and bringing significant efficiency gains to the client’s production line. The solution eliminated manual labor, improved product consistency, and significantly reduced downtime, providing both immediate benefits and setting the foundation for future scalability.
Ready to automate your production process and ensure consistency every step of the way? Explore our System Integration services and see how CAS can help revolutionize your operations.
Submit an inquiry for a custom quote today!
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About the Author: Rylan Pyciak
Rylan Pyciak, CEO of Cleveland Automation Systems®, is a Systems and Control Engineering graduate from Case Western Reserve University. With expertise in PLCs, robotics, and industrial engineering, Rylan leads CAS in delivering innovative automation solutions. Passionate about mentoring future trades professionals, he combines technical knowledge with a commitment to fostering sustainable growth in manufacturing.