Sometimes it can be too hot for a Robot

Robots are awesome for repetitive operations in harsh environments.

In this instance, a manufacturing plant was using a robot arm to remove parts from a molding machine. They were having issues with the electronics overheating.  They decided to do a thermal imaging scan, and they found that the heat was coming from their treatment furnace.  As you can tell with the image below, the high temperature (light orange color) was radiating onto the robot enclosure.  The temperature at the cover was at 60.6 deg. C (141 deg. F).  This was too hot for proper operations.  So, they contacted us to see if we could suggest a product to help keep their robot cool.

Thermal Image Temp = 60.6 deg C (141 deg. F)
Thermal Image
Temp = 60.6 deg C (141 deg. F)

In reviewing the elevated ambient temperature and the dimensions of the enclosure, I determined that our HT4215 High Temperature Cabinet Cooler would work great in this application. Our HT Cabinet Coolers are designed to handle ambient temperatures from 52 to 93 deg. C (125 – 200 deg. F).  They can be mounted easily onto the enclosure, and the internal profile is small as not to contact any of the components inside.  The Cold Air Distribution Kit (included with this model) can maneuver the cool air to the hotter areas and to the more sensitive electronics.

High Temperature Cabinet Cooler
High Temperature  Cabinet Cooler

Once it was installed, the robot was functioning without issues or shut downs. If you have issues in a harsh environments, please do not hesitate to contact one of our Application Engineers at 800-903-9247.  We may have something that can keep your operation running smoothly.

 

John Ball

Application Engineer

Email: johnball@exair.com

Twitter: @EXAIR_jb

There Must Be A Better Way To Save…

 

I’m writing this blog at almost the top-dead-center midpoint of Spring Break week. My teenage sons have been “enjoying” their time off thus far with the housekeeping duties their mother has been assigning them, and the labor they’ve been providing their uncle, as he installs a new garage door for us…the one my mother-in-law paid for. I definitely married out of my league.

The last half of Spring Break, though, we’re taking a little vacation. We looked at the activities and attractions at our destination, came up with a plan on what to do and when (including an analysis of the 10 day weather forecast…which prompted me to find our rain ponchos) and have even purchased some tickets in advance, because advertising “5% SAVINGS!” on stuff really works on me, even when it’s on a $20 ticket. Before you grab your calculator, yeah…that’s a dollar. But since there are four of us, I’ve multiplied our savings by 400%! Yes; I know…four bucks.  Still, I’ll take it.

We talk to folks almost every day who want, like I do, to save money on goods and services they’re going to purchase anyway. Some have performed comprehensive energy audits, and identified opportunities to lower their compressed air generation and/or consumption rates. Others have just been looking at the bent copper tubes that are blowing off their parts and thinking there has to be a better way.

(Full disclosure: I’ve had these two exact conversations so far this week.)

Today, I want to tell you about the latter: It’s an aluminum casting plant with about a dozen lines where a robot grabs a fresh casting from the machine, dips it in a quench tank, and holds it in front of an array of copper tube blow offs for a few seconds before placing it in a bin, bound for the machine shop. Not only were they blowing at it from both sides with the copper tubes, but they were also blowing continuously…including the majority of the cycle time that did NOT include holding the part in the air flow.  Dear reader, if you’re familiar AT ALL with the EXAIR blog, you’ll know that we simply cannot abide that. Continuous flow when flow is only needed a fraction of the time is wasteful and expensive. Not to mention blowing air out of open tubes is dangerous, loud and requires and unneccessary volume of compressed air.

It's like they WANT to upset us.  What's up with that?
It’s like they WANT to upset us. What’s up with that?

They installed (2) Model 110018 18” Aluminum Super Air Knives, in place of the copper tubing, which cut down on their air consumption…and noise levels…considerably. I gave them some further recommendations on reprogramming the robot to turn the part in front of one Air Knife, and using an EFC Electronic Flow Control to turn the air off when a part was not present.

EXAIR's EFC automatically turns the air off when a part is not present.
EXAIR’s EFC automatically turns the air off when a part is not present.

Is there a better way to use the compressed air in your facility? Whether you’ve got comprehensive data from a detailed audit, or if that open pipe is just too darn loud, all the time – give me a call…we’ll find out.

Russ Bowman
Application Engineer
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Help with Choosing an E-Vac Vacuum Generator

This is a pretty common question when it comes to Vacuum Generator use in pick-and-place application, and although we can’t boil it down to a simple table & formula based on mass (like we can with the Vacuum Cups themselves,) we can usually hone right in on it, if we have enough details of the situation. And, if questions remain, we can always test one to find out…we’ve got an Efficiency Lab.

That’s what I did, first thing this morning. I had the pleasure of speaking with a robotics instructor at a vocational school yesterday…his class was building a robot to enter in a competition, and one of the operations it needs to accomplish is picking up a golf ball and carrying it a certain distance.  This sounded like a great application for a small E-Vac Vacuum Generator, and, considering the potential leakage at the Vacuum Cup face from the dimples on the golf ball, my first instinct was to consider our Model 810002M E-Vac Low Vacuum (Porous Duty) Generator w/Muffler, and a Model 900766 Bellow Style Vacuum Cup, with a 0.73″ diameter face…our smallest, and ideally sized for a golf ball.  They, however, have a VERY limited supply of compressed air, so the difference between the Model 810002M’s compressed air consumption (2.3 SCFM @80psig) and the Model 800001M E-Vac High Vacuum (Non-Porous Duty) Generator w/Muffler (1.5 SCFM @80psig) was worth considering.  Also, we figured that they might be able to use a Model 900804 Check Valve, so the only time they’d need to supply air was to pick it up, and, possibly intermittently to maintain the vacuum.  So, golf ball in hand, off to the Efficiency Lab I went.  I also took our trusty video camera:

As you can see, it locked on to the golf ball instantly, and the Check Valve allowed the Vacuum Cup to hold the ball for over 13 seconds with no air flow to the E-Vac, proving that there isn’t much leakage at all past those dimples.  I suspect we’ll be seeing this robotics class team in the winner’s circle at the competition.

In most cases, the difference between 1.5 SCFM and 2.3 SCFM consumption may go unnoticed when picking a short-duration pick-and place vacuum generator.  The higher usage product’s supply pressure can always be regulated down to reduce compressed air consumption and use only what’s necessary to do the task…we, in fact, recommend that on ANY compressed air application.  In this case, though, it was worth finding out.

If you have a pick-and-place application that you’d like help with in selecting the right system, give me a call.

Russ Bowman
Application Engineer
(513)671-3322 local
(800)923-9247 toll free
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