Product category:
Robots and robotic systems
News Release from: Motoman Robotics (UK) | Subject: Robot
Edited by the Manufacturingtalk Editorial
Team on 28 February 2007
Robot machines and routes GRP bathware
A Motoman robot has taken over machining of glass reinforced plastic (GRP) bathware, which previously involved manually carrying out arduous, at Carefree Bathing.
At the Coventry factory of Carefree Bathing, a Motoman robot has taken over machining of glass reinforced plastic (GRP) bathware, which previously involved manually carrying out arduous, noisy and dusty trimming and drilling operations According to Russell Freestone, Carefree Bathing's Production Director, automating the routing operations results in monthly savings of GBP10,000 when the line is working to full capacity
This article was originally published on Manufacturingtalk on 14 Jul 2000 at 8.00am (UK)
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The cell paid for itself during the first four months of operation from April to July 2006.
The Motoman UP50-35 six-axis robot was supplied through specialist integrator, RobotSense, which programmed twenty four GRP trimming and routing cycles plus twelve chipboard machining programs for the different styles and sizes of walk-in bath manufactured for the elderly and disabled.
The remainder of the robot cell including the enclosure and fixturing were configured by Carefree Bathing, hence the relatively low investment figure.
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A family-run business, Carefree Bathing prides itself on hand crafting its products around a rigid steel frame and chipboard base to prevent deformation and water leakage.
The bath itself is made by spraying resin and chopped fibreglass to a thickness of up to 6 mm into a mould that has already been coated with coloured gel paint.
After curing, the bath is removed from the mould and undergoes 10 minutes of manual deflashing to remove most of the excess material.
The bath is transferred to the robot cell where the GRP shell is automatically finish-trimmed and the holes drilled for the jet spa system using a routing cutter in a high-speed spindle mounted on the wrist of the UP50-35.
A typical spa system can have 24 jets.
Due to the flexibility and speed of the Motoman robot, the cycle time has been reduced by 85 per cent compared with manual machining, allowing Carefree Bathing to cope with demand.
Commented Mr Freestone, "Last summer we were producing 200 baths per month, many for the US market, and saved GBP40 in labour costs per bath using the robot.
In addition, our outgoings are GBP2,000 less every month because we also machine our chipboard panels in the robot cell, instead of subcontracting out this work.
"Not only are we saving money, but automated machining has also eliminated a severe bottleneck in our manufacturing operation and boosted production output significantly." He went on to explain that as it is such an unpleasant and exacting job, manual trimming and routing of GRP and chipboard has always been the limiting factor in Carefree Bathing's production line.
Few people want to stand for 10 hours wearing goggles, a dust mask and ear defenders; and even if someone is prepared to do it, concentration is difficult and errors tend to creep in.
The consistency of the operators' work was variable, leading to quality issues, rework and scrap.
A robot, on the other hand, is impervious to the harsh environment and since the automated machining system was installed, problems have been eliminated.
Mr Freestone also commented that pre- and post-sale service from both Motoman and Robotsense has been very good.
He is now keen to automate other operations in the factory that lend themselves to being carried out by robot.
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