R2 Labs

Overview

                    This case study discusses the implementation of three
                        CNC machine-tending railed robots for a groundbreaking lights-out factory startup. R2 Labs used
                        the R2 Autonomy Controller (RAC) to construct the control system for this high-mix low-volume
                        environment. The robots were able to tend cells of CNC machines and execute work orders from the
                        facility Manufacturing Execution System (MES). This allowed for custom parts to seamlessly be
                        taken from through all phases of machining, post processing, and quality inspection.
                

Background

Machine downtime costs American manufacturers $50 billion per year. As labor costs and onshoring continue to increase, the manufacturing industry needs to adapt. Lights-out factories offer a solution to these growing demands as their complete automation can save businesses time and money by operating 24/7 with minimal human supervision.

R2 Labs was tasked by a cutting-edge manufacturing startup to build the software and install the hardware for multiple 4-axis CNC tending railed robots.

Solution

After installing the machine-tending robot, R2 Labs implemented the RAC to control and monitor all operations, thereby allowing it to do the following:

1. Link to the preexisting factory MES for timing and automatic loading and unloading of parts

2. Interface with AMRs for unloading work pieces and loading finished pieces

3. Communicate with CNC machines using OPC-UA

4. Handle all realtime motion and IO control tasks within the RAC Linux environment

5. Meet OSHA safety standards through use integrated safety PLCs and LiDARs

Shop personnel can now monitor and modify operations remotely, a critical step for nighttime use with minimal supervision

Results

R2 Labs installed three RAC-controlled robots that tended six CNC machines each. The RAC allowed for total remote control and monitoring of facility operations, allowing employees to have eyes on the plant at all times and to modify job orders from afar.

                    The automated machine tending controllers that R2 Labs
                        developed for this deployment gave the customer an automated system for machine tending and
                        material handling, demonstrating the real possibility of a fully lights-out factory. The
                        customer enjoyed greatly reduced labor costs due to decreased employment needs and operator
                        training requirements. The modularity and flexibility of the RAC allows for easy integration and
                        expansion into multiple pre-existing systems, such as the facility MES and commercially
                        available safety components.
                

                
It's time for a smarter way 
to control your equipment

CNC Machine-tending Robot

Overview

Background

Solution

Results

It's time for a smarter way to control your equipment

It's time for a smarter way
to control your equipment