Robotic System for Automating Plastic Injection Tank Removal at Everhard Industries
Client: Everhard Industries
Robotics Partner: Industrial Robotics
Technology Deployed: ABB IRB 8700, Australia’s Largest Industrial Robot
Event Highlight: Inside Advanced Manufacturing 2024 (IAM2024)
At the forefront of industrial automation, Everhard Industries partnered with Industrial Robotics to deploy the ABB IRB 8700—the largest ABB robot in Australia. This deployment was a part of Everhard’s efforts to streamline and automate the removal of large, 3000L plastic injection tanks and their lids from a Haitian injection molding machine.
Before automation, the manual process had a cycle time of 8 minutes per lid, meaning that during a standard six-hour shift (360 minutes), the maximum output was 45 lids. After the automation upgrade, the cycle time dropped to just 5 minutes per lid. This improvement allows for a maximum output of 72 lids in the same 360-minute shift.
This transition has driven a throughput efficiency improvement of 160%, highlighting the profound impact of automation on manufacturing processes. The faster cycle times not only increase output but also ensure consistent quality, reduced labor strain, and cost savings. No small feat when this is just stage one! The robot wil soon be extracting tanks and full ROI can be calculated.
The project was showcased at the Inside Advanced Manufacturing 2024 (IAM2024) event, held from September 2-13. This event, supported by Queensland’s Department of Regional Development, Manufacturing and Water, opened the doors of leading manufacturers across the state, showcasing cutting-edge technologies in real-world applications. Everhard’s presentation of the IRB 8700 attracted attention, demonstrating how advanced robotics can revolutionize manufacturing processes.
Project Overview
The objective of this project was to develop and implement an innovative robotic cell to remove 3000L plastic injection tanks and their lids, reducing manual labor, improving efficiency, and enhancing safety. This large-scale automation challenge required a combination of high payload capability, extended reach, and precise manipulation—all of which were achievable with the ABB IRB 8700.
Tank Specifications:
- Capacity: 3000L
- Weight: 120kg
Lid Specifications:
- Weight: 30kg
Gripper Components:
- Truss Gripper: 350kg
- Lid Gripper: 50kg
Key Project Components
In this project, Industrial Robotics played a critical role in designing and developing a fully automated industrial cell. The deployment of the ABB IRB 8700 robot, with its 4.2-meter reach, was integral to the automation of the tank and lid removal process.
System Design and Development
In line with ANZ Standards, our key responsibilities included:
- Design and modeling: Developed all cell components, including the robot stand, positioning, gripper support, truss gripper for tank removal, and lid gripper.
- Fencing and safety: Ensured the cell met safety regulations with properly installed fencing.
- Assembly and adjustment: Facilitated assembly and adjustment of all system components to achieve optimal performance.
Procurement and Coordination
- Sourced components through careful supplier negotiations, ensuring the best prices without compromising on quality.
- Managed procurement of essential hardware for the project, such as grippers and support structures.
Advanced Simulations and Analysis
- Conducted reach simulations to validate the IRB 8700’s ability to precisely interact with the tanks and lids.
- Performed Finite Element Analysis (FEA) to evaluate and optimize the structural integrity of the cell’s components under operational loads.
Field Work
- Collected precise field measurements to ensure seamless integration of the robotic system within the production line.
- Collaborated closely with Everhard Industries to adjust the system as needed during testing and commissioning.
Challenges and Solutions
A key challenge in this project was ensuring the robot’s reach and payload could handle the substantial size and weight of the 3000L tanks and their lids. The ABB IRB 8700, known for its superior strength and reach, proved to be the ideal solution. Additionally, the design of robust truss and lid grippers, capable of lifting and maneuvering the heavy tanks and lids, was crucial to achieving successful automation.
Conclusion
The implementation of the ABB IRB 8700 at Everhard Industries exemplifies how advanced robotics can revolutionize industrial processes in Aussie businesses, improving both efficiency and safety. The deployment of this robotic system not only streamlined the removal of large plastic injection tanks but also showcased the future of automation in large-scale manufacturing.
As highlighted at IAM2024, this project shows the importance of innovation and collaboration in industrial automation. Industrial Robotics is proud to have delivered this groundbreaking robot, with a robot onto stage two, and we look forward to future opportunities to push the boundaries of what’s possible in robotic automation.
Future Outlook
This successful collaboration marks another great outcome for automated systems deployed at Everhard Industries. Demand for more efficient and safer production processes is growing. Industrial Robotics remains committed to driving forward the next generation of industrial automation.
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