Modular Automation Compatible Products to Support Future Automation
With the Aim of Realizing Layout-Free Automated Equipment and Lines
Production sites require systems that can respond to changes in the field of manufacturing, such as labor shortages and shortened product lifecycles. In response, accelerated efforts are being made to automate the replacement of humans and modularize production lines. Oriental Motor has positioned these product groups that contribute to automation as "modular automation compatible products" and has begun offering these to customers. We interviewed Hiroshi YAMAKOSHI, Manager of the Product Planning Section in the Product Planning Department for the Sales Division at Oriental Motor, about the concept and overview of compatible products.
Keys to Automation "Automation to Replace Human Labor" and "The Modularization of Production Lines"
There exist labor shortages due to the decline in the working population, shortened product life cycles and high-mix, low-volume production, and production tailored to the specifications of each country due to global expansion. Today, gaining the flexibility to respond to such changes has become a top priority in the field of manufacturing. The major trends are "automation to replace human labor" and the "modularization of production lines."
"Automation to replace human labor" aims to eliminate labor shortages and improve productivity by automating simple tasks such as the supplying of parts to production lines and transferring between processes, which were previously performed by human workers.
"Common examples include the automation of transportation through dollies employing automated guided vehicles (AGVs) and autonomous transportation robots (AMRs), as well as transshipment automation and loading/unloading. In addition, we also use space-saving robots to automate detailed tasks that were previously performed by people, such as grabbing and processing," says Yamakoshi.
In the manufacturing industry, there is also a need to develop efficient production lines for high-mix, low-volume production in order to respond quickly to market changes, and to set up lines tailored to the markets of each country and region in the midst of global expansion. Conventional fixed production lines are not flexible enough to accommodate this. To address this issue, efforts are underway to "modularize" production lines by separating the equipment for each process and reconfiguring equipment configurations according to the situation.
This has expanded to a wide range of fields, including pharmaceuticals and consumer electronics manufacturers. "In the future, I believe that modularized production lines will be separated from each other, and that AGVs and AMRs will be used to automatically transport materials between them," says Yamakoshi.
Thus, it is not difficult to imagine the development of automation equipment and lines with "flexible layouts" and that flexible automation will develop to respond to changes.
Hiroshi YAMAKOSHI, Manager, Product Planning Section, Product Planning Department, Sales Division
Providing Modular Automation Compatible Products That Support “Layout-Free Automation"
Oriental Motor has positioned product groups that support these needs as "modular automation compatible products" and is suggesting the same to customers. This product group is based on the concept of being battery-driven (DC power supply input), compact, and lightweight, and is ideal for installation in self-propelled equipment and modularized equipment. Layout-free automation helps to eliminate labor shortages, improve productivity, save space, and enable high-mix, low-volume production.
In general, the voltage of a battery rises slightly when it is fully charged, and falls as the voltage decreases. Modular automation compatible products are those that have the performance to support this. The driver is also very small and lightweight, allowing it to be integrated into any available space in the equipment, even when a control cabinet is not available.
Two series of modular automation compatible products are available – the "BLV series R type brushless motor" ideal for AGVs and AMRs, and the "AZ series DC input mini Drivers, motors and actuators" ideal for automatic machines mounted on AGVs and AMRs.
The BLV Series R type is a product that is suitable for the AGV and AMR wheel drive, which can operate at low speeds starting from 1 r/min and realize a smooth drive. Both the motor and driver have been made significantly smaller and lighter to help develop more compact battery-powered devices. It features high-strength with a radial load of 1500 N (153 kfg) when the flange drive adapter is assembled, and a maximum radial load of 2040 N (208 kfg) for the hollow shaft flat gear, meeting the needs for larger workpieces, robot and conveyor mounting, etc.
The AZ series DC input mini driver and motor actuator is a product group designed for conveyors, elevators, and robots mounted on AGVs and AMRs. The lineup includes DC input motors, hollow rotary actuators, rack-and-pinion systems, electric linear slides, electric grippers, and compact electric cylinders. The αSTEP, which employs Oriental Motor's unique closed loop control, is equipped with an ABZO sensor to realize an absolute system that eliminates the need for a home position or other sensors, without the need for a battery. The mini driver has a compact and lightweight design for embedded applications and to reduce control cabinet space, and supports network control such as EtherCAT and RS-485 to reduce wiring.
Examples of Adoption in Transportation Robots and Modularization
We are currently receiving many inquiries about "automation to replace human labor." A major electronic components manufacturer has introduced a delivery method in which a high-quality, AGV-equipped top-loading robot, in which αSTEP and a brushless motor were adopted, can grasp and transport electronic parts, and deliver them to clients.
"Brushless motors were chosen for the wheels because it required powerful speed-controlled motor gears that could be powered by a battery, and required small drivers that could fit into a highly constrained installation space. The key points in adopting αSTEP for the work robot were so that it could meet our needs for a motor that could be battery-driven and controlled with high precision, and had a compact and lightweight motor and a driver with a small design requiring fewer wires and a high degree of freedom in terms of placement location in relation to space and weight constraints," said Yamakoshi.
"Many companies have been working on "modularization" for some time, and we have been consulting with them on issues related to downsizing and space saving in particular.
"In the modularization process, it is important to select components that are compact and lightweight, since the equipment and electrical components must fit within a limited width, height, and depth to reduce the size of the equipment. Another key point is to support DC power supply and network control in order to make it easier to separate the power supply and wiring for each module. Our mobile automation-ready products, which include compact and lightweight network-controlled DC input products, will help solve issues in modularization," says Yamakoshi.
Customers' plans and needs vary, and Oriental Motor will contribute to efforts toward realizing layout-free automation through its modular automation compatible products and services. We will propose solutions to the issues faced by our customers, with a focus on "automation to replace human labor" and "modularization," so please feel free to contact us with any questions.
Support for Equipment Design from the Product Selection Stage
- A full-time member of staff will select a motor on your behalf.
- Materials related to equipment specifications and dimensions of our in-house manufactured equipment are available.
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