Integration of robots and vision systems in machine manufacturing - what does it look like in practice?

Estimated reading time: approx. 10 minutes

TL;DR

• Robots provide high repeatability and facilitate flexible machine production.
• Vision systems enable rapid quality control and precise part recognition.
• Integration requires the right choice of equipment, a testing stage and calibration.
• The increasing complexity of projects and short production runs are encouraging job automation.
• Support from an experienced integrator minimises the risk of errors and reduces implementation time.

Table of contents

• Introduction
• Why is the integration of robots and vision systems becoming standard in machine manufacturing?
  • Increasing complexity of projects and quality requirements
  • Personalisation and short series
• Seven key steps in the integration of robots and vision systems
  • Needs analysis and concept preparation
  • Choosing the right equipment
  • Job design
  • Simulation and offline testing
  • Hardware and software integration
  • Calibration and optimisation
  • Final testing and acceptance
• Key benefits of integrated robotics in machine manufacturing
  • Higher quality and less waste
  • Protecting employees and assigning them more creative tasks
  • Reducing time to market
• The most common challenges in integrating robotic workstations with vision systems
  • Compatibility and communication standards
  • Stability of lighting and working conditions
  • Costs and return on investment
• Examples of practical implementation - inspiration and figures
• Support from an experienced integrator
• Natural internal links - expand your knowledge of robotisation
• Practical lessons - what is worth bearing in mind when planning integration?
• Summary
• FAQ

Introduction

Machine manufacturing is one of the key sectors of the economy, providing not only highly specialised equipment, but also solutions to support the development of the entire industry. Today's expectations of manufacturers can range from the need to speed up production processes as much as possible to maintaining the highest quality standards. In addition, many companies want to flexibly adapt their lines to specific requirements (e.g. short production runs), which in practice means integrating increasingly sophisticated systems.

In this article, we provide an overview of the key steps and challenges of integrating robots and vision systems in machine manufacturing. You will learn why such integration is becoming increasingly popular, what effects you can expect and what elements should be taken into account already at the design stage of a new line or its upgrade.

This article will give you specific tips on:

• Ways to effectively use robots (including the SIASUN brand) in machine manufacturing.
• The steps necessary to carry out the correct integration of vision systems into the various modules of the production line.
• The main benefits and challenges accompanying the implementation of robotic workstations and image analysis systems.
• The importance of supporting experienced integrators such as Michale Automation.

Why is the integration of robots and vision systems becoming standard in machine manufacturing?

One of the most important trends in industry is the move towards more automation and robotisation. Until a few years ago, industrial robots were mainly associated with the automotive industry and mass production. Today, they are used in almost every factory, regardless of the size of the company.

Increasing complexity of projects and quality requirements

In modern machine manufacturing, it is no longer enough to simply 'assemble' a product according to the documentation. Machines have to be:

• Flexible - able to adapt quickly to different models or product formats,
• Fully integrated with other equipment - so that the operation of the line is not impaired,
• Highly efficient - aiming to reduce cycle times as much as possible.

The use of robots enables assembly, welding or handling tasks to be carried out with precision, resulting in stable quality in the production process. As the line becomes more complex, vision systems become crucial. They enable automatic object recognition (e.g. of parts or components), quality control, dimensional measurement or rapid fault detection, which reduces the percentage of defective parts.

Personalisation and short series

Machine manufacturers are increasingly faced with the need to quickly reconfigure their lines. Customer-specific projects sometimes require short runs and a diverse range of products, so automated workstations must be easy to reconfigure. Robots bring unrivalled value here - they can be reprogrammed for new tasks without implementing costly and labour-intensive mechanical modifications.

Seven key steps in the integration of robots and vision systems

Although every project looks slightly different, a few universal steps can be identified to help plan the successful integration of robotics and image analysis systems in machine manufacturing:

Needs analysis and concept preparation

Before starting the design, it is worth specifying which tasks the robot will perform and which process areas are to be covered by the vision system. Is it assembly support, quality inspection or component picking, for example? At this stage, it is crucial to determine the requirements in terms of production speed, accuracy or measurement range.

Choosing the right equipment

The choice of robot depends, among other things, on the payload, arm reach or specific movement. Michale Automation is an official distributor of SIASUN robots, which feature a wide range of capabilities, from lightweight cobots with short reach to heavy units capable of handling workpieces weighing tens of kilograms.

The next step is to decide on a camera or an entire vision system. This could be a simple 2D camera for detection and quality control or a complex 3D system for advanced measurements.

Job design

Once the machine production objectives have been defined and the components selected, it is necessary to plan the workplace in such a way that:

• Ensure proper ergonomics (for humans working with the robot),
• Take all safety requirements into account,
• Facilitate possible future modifications,
• Optimise material flow and guarantee line continuity.

Simulation and offline testing

Current CAD/CAM tools enable detailed simulation of the robot and vision system. This allows early detection of possible collisions or difficulties in locating components, checking cycle times or assessing whether the robot's reach is sufficient.

Hardware and software integration

When all the components arrive on the production floor, the physical connection of the robots, sensors, cameras and peripherals takes place. In parallel, programming work is underway, including configuration of the vision system: selection of lens parameters, lighting, object recognition algorithms.

Calibration and optimisation

It is extremely important that the vision system 'understands' the robot workstation. To this end, a calibration process is carried out, which involves precisely correlating the image coordinates with the actual coordinates in the working area. After implementation and initial commissioning, it will not be impossible to make adjustments - e.g. changing the camera exposure parameters, optimising arm movement, correcting the gripper.

Final testing and acceptance

The final stage is to verify the operation of the production line in all assumed operating variants. If the station has an additional module, e.g. an automated packaging station, it is also worth carrying out tests under conditions simulating the actual load.

Key benefits of integrated robotics in machine manufacturing

The integration of robots and vision systems is not just a fashionable buzzword - it brings many tangible benefits that, for machine manufacturers, often determine the profitability of an investment.

Higher quality and less waste

Robots are characterised by high repeatability, which translates into a reduction in the number of defective parts produced by the machine. If we add ongoing quality control (e.g. 2D/3D cameras identifying defects or misaligned parts), we find that the integration of these solutions significantly reduces material and service wastage.

Protecting employees and assigning them more creative tasks

Many processes involved in machine manufacturing involve repetitive sequences of movements or working in harsh environments (e.g. high temperature, dust). Robots are ideal for such environments, taking over monotonous and hazardous tasks. Human staff then gain time for conceptual work or quality supervision, increasing the efficiency of the entire plant.

Reducing time to market

Thanks to the rapid changeover of workstations, robots are able to handle different project phases flexibly. Introducing a new machine model or changing the size of a batch often does not require expensive and time-consuming modifications - all that is needed is the right programme and minimal parameter adjustments.

The most common challenges in integrating robotic workstations with vision systems

While the benefits seem obvious, anyone planning to invest in machine manufacturing with robots and vision systems is faced with potential difficulties.

Compatibility and communication standards

Robotics systems require integration with a wide range of devices: from PLCs to HMIs to advanced vision modules. Communication protocol standards (e.g. EtherNet/IP, Profinet, EtherCAT) are crucial. If equipment from different suppliers is running on the line, it will be necessary to verify that all components 'get along' with each other before implementation.

Stability of lighting and working conditions

For vision systems, the conditions under which image analysis is carried out are of great importance. Varying light intensity or reflections from metal parts can interfere with object recognition, causing incorrect decisions by the robot (e.g. incorrect workpiece position indication). This is why special LED light sources, optical filters or housings that reduce the influence of daylight are often used.

Costs and return on investment

An expanded machine production line with its own vision system involves expenditure on hardware, software and integration. Many investors wonder whether the costs will prove too high in relation to the benefits. In practice, however, the right choice of robot and professional implementation results in significantly faster production and higher quality. This translates into lower waste costs, a lower risk of complaints and sustainable savings in the area of human resources.

Examples of practical implementation - inspiration and figures

Both small and large manufacturing companies are increasingly boasting of their success in introducing robotic workstations with vision systems into their machine production lines. In a survey conducted by the industry organisation IFR (International Federation of Robotics), as many as 77% companies saw a clear increase in production efficiency in just the first year after implementing robots.

Here are some specific examples of applications:

• Precision assembly process: Robots with a payload capacity of 12-25 kg (e.g. the SR25A series from SIASUN) equipped with pneumatic grippers and vision systems perform well in the assembly of machine components with complex-shaped parts, where any small irregularity in component spacing can cause failures in the finished unit.
• In-line quality control: Special 2D cameras make it possible to verify the correct assembly of individual components, e.g. whether all assembly screws are in the right places or whether weld seams comply with safety standards.
• Packaging and palletising: Although often associated mainly with the food industry, automated packaging stations are increasingly appearing in machine manufacturing. Many of the items manufactured in the process need to be safely packaged before further transport or storage.

Support from an experienced integrator

Due to the complex nature of machine manufacturing processes, it is good to work with companies that have practical experience in integrating robots and vision systems. Michale Automation specialises in the design and implementation of modern solutions including:

• Construction of machinery and production lines,
• Automation of industrial processes,
• Implementation of robotic workstations based on SIASUN robots,
• Integration of vision systems, sensors and PLCs with other line components.

With the knowledge and experience of an integrator, many common mistakes made during amateur implementations can be avoided, downtime can be reduced to a minimum or the testing process can be accelerated. If you are looking for solutions in the area of streamlining repetitive processes that require a high degree of precision and speed, also check out our offer
Robotisation of repetitive production - there you will find more concrete tips on how to automate key steps in the manufacture and packaging of machine components.

Natural internal links - expand your knowledge of robotisation

If you are interested in how robots can support other processes in machine manufacturing, the following resources are worth reading:

• Robotisation of packaging - useful information on packaging automation, which is also essential for shipping finished machine components.
• Service and maintenance of robotic workstations - Proper maintenance ensures high reliability and prolongs the life of machines and robots.
• ROI calculator - developed for welding robotics, but the calculation mechanism also works well in other applications.

Practical lessons - what is worth bearing in mind when planning integration?

Here are some of the most important tips to consider if you are planning to expand your line with robots and vision systems in the context of machine manufacturing:

1. Define objectives at the start
   Determine what is a priority: fast cycle times, high accuracy, flexibility or minimising downtime. Match the choice of technology (type of robot, camera, controller) to clearly defined requirements.
2. Ensure consistency of communication throughout the environment
   Verify controller protocols, input/output standards and production management software. Machine manufacturing often uses ERP/MES systems that need to receive and send data to robots and cameras.
3. Remember safety
   Robots, especially those with high payloads, require adequate safety zones. Enclosed cages, optical barriers or safety systems can be indispensable.
4. Conduct simulations and tests before final implementation
   The ability to virtually check the robot's path and correctly identify parts through the camera results in significant time savings and eliminates errors right from the design stage.
5. Secure funds for post-implementation support
   Even the best project may need tweaking after launch. It is worth agreeing with the integrator on a quick service response and possible online support.

Summary

Machine manufacturing is constantly evolving: from mass production and simple assembly processes to precise, highly automated lines guaranteeing short runs and individual modifications. In this context, the integration of robots and vision systems is becoming a cornerstone for those companies that want to stay ahead of the competition and meet market demands for quality and flexibility.

The key benefits of an integrated approach are:

• Increased productivity while reducing errors and waste.
• Flexibility to adapt the production process to different customer requirements.
• Improved safety and ergonomics for those operating the line.
• Faster time to market for new machine models and the ability to adapt the line to meet the needs of changing projects.

If you are considering the implementation of industrial robotics in your plant - whether you are producing complete machines or just some selected modules - you can always benefit from the advice of experienced specialists. Michale Automation deals with the complex integration of SIASUN robots, as well as the development and optimisation of existing lines in line with the latest Industry 4.0 trends.

We encourage you to explore the topic further by reading related articles on the company's website, including on robotic packaging and maintenance of robotic workstations. We also look forward to your comments and questions - if you would like to find out more, please feel free to contact us or subscribe to our newsletter.

With the seamless integration of robots and vision systems, machine manufacturing can enter a new, higher level of efficiency and quality. It is an investment that - with professional support - will provide your company with real benefits.

FAQ

How long does it take to implement automation in a company?
The implementation time depends on the complexity of the processes and available resources. It can range from a few weeks for simple solutions to several months for extensive projects and large integrations.

Does automation mean redundancies?
Usually no. Automation allows employees to focus on more creative and strategic tasks, while freeing them from monotonous tasks. Many companies use this to retrain and develop their team professionally.

Does robotisation only pay off for large companies?
Today, more and more small and medium-sized companies are opting for robotisation. Thanks to falling costs and the increasing availability of solutions, flexible robotic systems can pay off even at smaller production scales.