Projects to Increase Efficiency of Manufacturing Process
Achievements in Production Process Efficiency Development
Robot Project for Collecting Metal Scraps (Crop Collector System)
FIBO (Institute of Field Robotics) has collaborated with Siam Yamato Steel Co., Ltd. on an ambitious project: to design and build a large-scale industrial robot system for their hot-rolled structural steel (H.I.C) production line.
This innovative robot is designed to handle metal scraps (“หางเหล็ก”) weighing 300 kilograms and ranging from 500 to 2,000 millimeters in length, all while at a scorching 900 degrees Celsius. The robot can retrieve these scraps from the production line within 10 seconds and dispose of them within 50 seconds.
Automatic Rubber Loading Machine (ARM) Project
The current process of producing rubber blocks heavily relies on human labor to manually pull rubber blocks from trays. This repetitive and strenuous task often leads to fatigue among workers over long periods.
To address this, the team has researched, designed, and built a robot to replace human labor in this process. The developed robot features five grippers capable of picking up five rubber blocks at a time. It can move both horizontally and vertically, allowing it to efficiently pick up the rubber blocks and place them onto a conveyor belt for the next stage of the production process.
Automatic 2-Axis Welding Machine Project (Automatic System for Part Assembly)
Auto Summit Body Company has partnered with FIBO in a collaborative research and development project. This collaboration involves applying automatic production system technology to design and build an automatic part assembly system. This system will be utilized for spot welding in the manufacturing of automotive parts.
Project: Automated System for Manufacturing Hard Disk Drive (HDD) Ramp Assemblies
NOK Precision Components (Thailand) Co., Ltd., a leading manufacturer of high-precision components for computer storage units (Hard Disk Drives), has partnered with the Institute of Field Robotics (FIBO). This collaboration aims to double the production rate of their Hard Disk Drive (HDD) head suspension assemblies (RAMPs) to meet increasing customer demand.
NOK Precision Components (Thailand) has entrusted FIBO with the task of developing an automated system to be integrated into the RAMP manufacturing process. The scope of work for FIBO includes:
1. Studying and designing the overall layout of the automated system.
2. Designing the structural and mechanical systems of the equipment.
3. Developing the control system and user interface.
4. Overseeing the construction, assembly, and functional testing of the system.
Project: System for Reading and Analyzing Torque Values from HIOKI Wave Comparators
Minebea (Thailand) Co., Ltd., a manufacturer of high-precision electronic and mechanical components for the computer industry, recognized the importance of analyzing data from Ball bearing inspections to assess production process efficiency.
To this end, the company partnered with FIBO to develop a system for reading and analyzing torque values. This system utilizes Max, Min, Average, and Peak-to-Peak data from measurements. The resulting analysis will pinpoint defects in the production process.
The project is divided into two main phases:
Phase 1: Involves connecting data from the Wave comparators and designing the network layout for 150 Wave comparators. A central server will store all collected data.
Phase 2: Focuses on the design and development of statistical data analysis software.
Project: Design and Prototype of an Automated Production Line for HSA Manufacturing
This project involves the comprehensive design and prototyping of a semi-automated Head Stack Assembly (HSA) production line. The design strategy focuses on modularizing existing manual equipment, integrating them into a system where a conveyor belt transports workpieces sequentially through every step of the HSA production process. Each machine within the process is designed as a “Generic Cell” to facilitate easier maintenance.
This automation line is a collaborative effort between Western Digital (WD), NECTEC, FIBO, and four Thai SMEs operating under the name TH-Alliance. The project’s objectives are multifaceted:
For WD: To build expertise in creating machinery and automation systems that cover the entire HSA production process for 2.5-inch hard disks, with adaptability for future new products.
For NECTEC: To foster the domestic industry by developing skilled personnel in high-precision component manufacturing. This also promotes the transfer of technology and involves company personnel in research and development, who will become crucial for future in-house machine development tailored to the company’s products. It aims to disseminate and transfer hard disk component manufacturing technology within Thailand’s industrial sector, bringing in foreign academics and engineers, and facilitating technology transfer from educational institutions to local industries.
For Universities (FIBO/KMUTT): To cultivate personnel with knowledge and understanding in building high-precision machinery and to comprehend the process of writing control commands for machines to international standards.
For Participating SMEs (TH-Alliance): To enhance their capabilities and development within the Thai industrial landscape.
Project: Development of a Dust Sampler Conveyance System for Urban Climate Analysis
The Hydro and Agro Informatics Institute (HAII) requires in-depth atmospheric dust sampling to gather crucial data for Thailand’s meteorological studies. This involves collecting dust samples from equipment installed on tall weather masts. Currently, personnel must manually bring these sampling devices down to the ground for analysis, a process that carries high risks for both the operator and the delicate equipment.
To mitigate these dangers, the Institute of Field Robotics (FIBO) is leveraging existing vertical transport technology. FIBO is designing a dust sampler conveyance system that operates with vertical movement, similar to a hoist in a transport lift. This system will replace manual operation, making the process of collecting dust samples faster and more convenient for personnel, thereby facilitating the subsequent analysis of atmospheric particulate matter for climate assessment.
Project: Development of a Prototype AGV Mobile Platform
The Institute of Field Robotics (FIBO) has undertaken the development of a prototype Mobile Platform for Automated Guided Vehicles (AGVs), intended for use in industrial factory production processes.
This project focuses on creating the fundamental driving structure for a prototype AGV designed for transporting workpieces within closed factory environments. Additionally, it involves developing the navigation software and motion control system to enable the AGV to automatically move and transport workpieces to various stations along the production line.
Automated Pipe Insulation Foam Cutting System Project
Aeroflex Co., Ltd., which currently uses foam cutting machines for pipe insulation that require highly skilled operators, is facing challenges in finding qualified labor. To address this, the company sought to develop and implement an automated solution.
Aeroflex has partnered with FIBO (Institute of Field Robotics) to research and design an automated pipe insulation foam cutting system. The goal is to ensure precise cutting dimensions and flexibility for a variety of insulation sizes. The new system is also intended to be user-friendly, aiming to increase production capacity, maintain product quality according to manufacturing standards, and simplify operational complexity.
Project: Design and Development of an Automated Canning Line Sorting System
Unicord Public Company Limited sought to enhance its production process, aiming to increase efficiency and reduce reliance on manual labor. This initiative was driven by the persistent challenges of labor shortages, minimizing errors, and lowering production costs. The process of sorting canned food was identified as a key area still heavily dependent on human workers.
While introducing a robotic arm alone could reduce human labor, the high investment cost made it economically unfeasible. Recognizing this need, the Institute of Field Robotics (FIBO), with its expertise in robotics and automation, proposed an innovative solution.
FIBO’s concept involves designing a canned food sorting system that minimizes the use of expensive, large robotic arms. Instead, it leverages mechanical aids for conveying and arranging the cans. This approach ensures the system operates efficiently at a lower cost compared to imported systems or those relying solely on robots, making it a more suitable and cost-effective investment for Unicord.
Project: Development of a High-Pressure Waterjet Meat Cutting Machine
King Mongkut’s University of Technology Thonburi (KMUTT) has a collaborative partnership with CPF Public Company Limited (Thailand). As part of this collaboration, CPF (Thailand) is particularly interested in utilizing automation to enhance the efficiency of their production processes.
Trusting the capabilities of the Institute of Field Robotics (FIBO), CPF has assigned FIBO the task of developing a prototype automated system for use in CPF’s production processes. This initiative aims to significantly increase production efficiency, help reduce losses related to personnel, time, and the high cost of purchasing expensive machinery, thereby leading to a reduction in the company’s overall production costs. Ultimately, this project will enhance CPF’s competitiveness within the industry.