The path of factory innovation is leading us to automated systems rather than true robotics. Though industrial robotics has been used for 30 years in our industry, it has served mainly as a forerunner to later systems. Its earliest commercialization, the robotic arms of the Koskovich component saw, is being displaced by linear sawing systems. Its most ambitious adaptation, the robotic-aided truss assembly by Jim Urmson, has not progressed. And today’s most advanced system, Randek’s AutoEye, employs no robots.
Let’s examine each fabrication step and follow the evolution of technology:
- Picking lumber: Jerry Koskovich pioneered a bunk and magazine lumber feeding system on his linear (Miser) saw, and not, significantly, on his much more popular component saw. The two-bunk limitation of this system was overcome much later by the Wood Runner (and now the Ranger) retrieval system(s).
- Feeding the saw: Linearly feeding lumber to saws became the preferred method overseas in order to safeguard operators, but only lately has it become the American standard. Linear saws enable pre-marking along the entire length of boards, and insure more precise lengths and cutting angles. Accuracy of cuts is crucial when fitting automated jigging (see 4 below).
- From saw to the table: Jim Urmson further leveraged the linear saw by exiting cut parts directly onto a conveyor paralleling the truss table. Later he employed robots to feed lumber to the jig. Recently, CM’s have optimized this task either by reducing the distance—moving saws close to tables—or by reducing the time—using fast and maneuverable Combilifts (Shelter).
- Setting the jig: Virtek projected the truss perimeter and joint geometry. Koskovich and Alpine introduced “pucks-on-acme-screw” setup systems that had design limitations, but were forerunners to today’s widely used Planx and Wizard systems. Urmson employed automated pedestals to form the jig.
- Stitching members: Urmson added stapling fixtures to the robot’s arms to secure joints and outside perimeters.
- Fetching and pressing connectors: Urmson and Randek both innovated a magazine fed conveying system that delivered truss plates to magnetic hydraulic press heads.
- Controlling plate placement: Randek employs a state-of-the-art vision system to insure accuracy of plate placement. Urmson mechanically secured the truss perimeter until pressing cycle.
- Shop floor software: Advance planning, measurement of workload, and communication of data to projections screens and automated equipment optimizes the entire production process.
In summary, automation has evolved to smoothly direct materials through the production process, without robotics. Though Randek has but one U.S. installation, the remainder of the above systems are rapidly being deployed piecemeal across the country to great success.
Next Month:
The future of the Blueprint Robotics plant in Baltimore