Can Part/Job Changeover be Automated?

In today’s post, I want to cover a topic we get asked about a lot, which is automating part and job changeover – is it possible and how do you do it? 

The following is a brief summary, for a deeper dive you’ll want to download our Complete Guide to Robotic Machine Tending Projects. 

Part and job changeover complexity presents a challenge for basic robotic machine tending set-ups especially when the robot is not connected or communicating with the machine it is running. 

This is especially true in high-mix environments such as medical device contract manufacturers and aerospace suppliers where a variety of parts must be processed on the same machine. 

In many cases achieving automated changeover requires an Advanced Robotic Machine Tending configuration. 

Just like CNC machines have programs, robots require programmatic instructions for each part and job type. So for a basic CNC-to-robot configuration each part involves a program for the CNC and a program for the robot. 

In more sophisticated setups involving multiple machines and inspection equipment each part will have a program for each machine included along with the robot. Each changeover requires synchronized program loading so the robot and all associated machines get the correct program for the part that will be processed.

A helpful way to approach this is to recognize that nearly every mechanical change – whether switching parts, adjusting workholding, updating CNC tooling, or changing robot grippers – typically requires a corresponding software adjustment. 

When managing these part and job changeovers across multiple machines, software program loading adjustments can quickly add up, creating a significant burden to manage without mistakes unless robotic production software is in place.

A powerful robotic production software solution like Flexxbotics automates the changeover process by providing features like automatic program loading, variable setting, and real-time parametric adjustments. 

This transforms the hundreds or even thousands of software adjustments required in a factory with dozens of robots into a quick and efficient automated process. 

Additionally, operators can schedule multiple, sequential changeovers – with line clear for compliance if required – as long as the necessary mechanical aspects are in place as well.

Flexxbotics reduces changeover complexity by completely automating all aspects associated with robot and machine programs during changeover, as well as, providing the option to use barcode scans of the ERP or MES traveler for job changeover with automated program loading and adjustment setting to assure coordination when enabled.

Other changeover considerations that should be taken into account during the design of the robotic machine tending installation include:

• Is the part presentation area sufficient for the full range of parts?
• Do the machines’ workholdings cover all the different part geometries?
• Will the robot’s end-of-arm tooling be sufficient to pick up and hold all the different parts?

When running a variety of parts in a robotic machine tending setup, using zero-point pallets and adaptive technologies can significantly enhance flexibility and efficiency. 

Palletized workholdings help streamline part positioning for consistent, repeatable operations. In addition, using palletized vises for the end-of-arm tooling (EOAT) can enable the reuse of existing workholdings for parts with different geometries, weights, and materials. 

In other situations, dual EOAT grippers can be used to increase throughput by handling multiple parts simultaneously while multipurpose EOATs can enable quick transitions between tasks without manual intervention. Another option is force-feedback grippers which can allow for precise handling of ductile or fragile materials. 

An automated changeover process can significantly reduce downtime and make it feasible for robots to handle frequent changeovers for numerous part types without operator involvement. 

Without a solution such as Flexxbotics that includes an automated software changeover process, these tasks can introduce unnecessary downtime and slow production, reducing the efficiency gains of robotic automation.

In addition to our complete machine tending guide, we have a range of practical tools that will help assure your robotic machine tending initiatives are a success in our Papers & Materials section here or get in touch with us to discuss your project requirements today.