Enclosures: dumb, boring, and a savior for automation.
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Industrial modular machine enclosures don’t plug in, and there’s no software – which is why smart design is critical for your team’s safety and efficiency.
Specific to the framing in the base and guarding, there are several robotics safety rules you should follow. These guidelines will not only help you make safety features that are actually safe; they’ll also save a ton of money. (In one case, we’re talking paying $1,000 vs. $35,000.)
Robotics Safety Rules: From Stability to Strength
Industrial automation safety means starting at the foundational basics. An enclosure’s base and guarding should account for:
- Cyclic loading
- Access
- Size
- Integration & flexibility
- Safety
Rule #1: Cyclic Loading
Imagine you’ve bought and assembled a new Ikea bookshelf, but your partner changes their mind almost daily about the room’s feng shui. If you frequently move the unit back and forth across the room, it’s going to fall apart quickly.
On the production line, you want robotics that can rotate safely and reliably … which is why traditional T-slot extruded framing isn’t the best choice. These static applications involve frequent cyclic loading. Ideally your assembly will stay put during that repetitive stress, but that’s rarely the case, as these examples show:
- A robotic arm mounted to traditional T-slots will loosen with vibration, which may in turn misalign the machine’s safety guarding.
- A lot of conveyor systems use T-slots for the entire assembly, and thus require frequent retightening and realignment.
While the material itself is actually deceptively strong, its connections don’t hold in dynamic situations, leading to a short service life. For those in the “T-slots for everything!” club, industrial enclosure solutions tend to go one of three ways:
- Use the status quo, watch the assembly falter, then go back and drill and add brackets
- Overdesign to make sure it doesn’t slowly fall apart
- Keep a full-time welder on staff to patrol machine stations and weld any weakening T-slot connections
If you want the benefits of aluminum in a robot enclosure, you’re not out of luck – you just need an advanced extrusion frame. Self-aligning aluminum systems are an evolution of sorts for T-slots in that they’re modular and lightweight, but also sturdy and reliable. Thanks to advanced engineering of fasteners and brackets, these enclosure frames are manufactured to stay precisely aligned – even with repetitive motion or vibration.
Rule #2: Access
Overdesign and under-engineering are running themes with automated machinery enclosures.
T-slot enclosures feature heavy cross-bracing and bolting to make the structure more rigid. An excess of components makes human intervention inconvenient and unsafe when you want to make changes to equipment or access the enclosure’s door.
Look at a standard robot pedestal – a simple 1x1x3 frame bolted to the ground, with protective fencing. Almost every commonly available kit includes huge profiles and base plates. Just one corner of a T-slotted guard can include more hardware than an entire frame made with a different solution.
Welding steel produces much stronger bonds, reducing the number of support components you need. However, the savings are limited because steel framing carries an inferior strength-weight ratio vs. aluminum framing.
If aluminum is viable in your application, the solution once again is to high-end extrusion framing. Because self-aligning systems feature mechanically locking connections, they allow the assembly to use the full strength of each profile. The slip-proof bonding, combined with superior strength per pound, makes these framing systems the best of both worlds.
So, what if a human does have to access the device? Popular safety design features include access ports and viewing windows. These allow operators to monitor functions and collect data without opening the enclosure.
Sometimes, though, the door must open. And that’s when the fun danger begins.
Sagging enclosure doors produce unwanted maintenance downtime. The source is the same as above: crudely engineered extrusions with tough-to-align components. Failures around a door or window can’t be saved, but you can install a sturdier aluminum frame around the opening. This enables you to replace the existing door, but keep the rest of the enclosure, saving 95% of the replacement cost.
Rule #3: Size
Automation enclosures are more than just a fixture and a door – they take up valuable space on a manufacturing floor.
A bonus of designing for operator access is that it’ll also reduce the assembly’s:
It’s often possible to reduce 75% of the connective components in a T-slot frame by redesigning it with more sophisticated engineering.
A lightweight framing system is likely to be easier to assemble and transport, while opening space and visibility on the line.
Just remember to leave room for safe use – and expansion if you think the enclosure’s use may evolve over time. Even enclosures embedded in machine frames tend to receive little breathing room from the installer. Don’t be that guy – confirm the assembly will have sufficient space for safe access and opening.
Rule #4: Integration & Flexibility
You’ve seen the hints, but now let’s spell it out.
Typical automation enclosures combine a welded steel base with aluminum T-slot guarding. As such, one half has the pros and cons of welded steel, and the other half has the pros and cons of T-slots. Neither half of the assembly is fully optimized for both durability and modularity.
Today, it’s possible to integrate an automation machine base and enclosure into one assembly.
There are several advantages to a custom, one-piece industrial enclosure. Many directly relate to the other design considerations above:
- Fewer points of failure
- Improved operator access & sight lines
- Streamlined ordering & assembly – base and enclosure can share some supports
- More adjustable
- No miscommunications or drawn-out lead times passing the project between vendors
- Uniform aesthetic
The right aluminum structural framing can help you take this modular approach to the automation line.
Extrusion framing systems can easily accommodate accessories and join with other similar products, allowing nearly limitless iterating. If your needs shift, you can make modifications without excessive downtime or hiring a welder.
Rule #5: Safety (Would You Trust the Enclosure With Your Life?)
A final, very simple guideline for machine frame design: If the enclosure won’t come through in the clutch, why bother?
If you’ve stepped foot on a manufacturing floor, you know there’s a lot of powerful, moving machinery and the chance for dangerous flying debris. If a metal enclosure design fails, something could launch directly toward a human being.
Make sure your guarding provides actual safety, instead of the illusion of it. A flying robot arm would easily barrel through many of the safety guards we see in real-world use.
This is where up-front strength matters just as much as long-term stability. Steel framing is hard and strong. Self-aligning aluminum framing is strong. T-slots are neither because they rely on friction and pivots to connect and align profiles.
Yes, workers wear safety glasses and other protection, but things happen. Use the right framing for high-risk applications.
Being the AI for your Robot Safety Design
Unlike the “brain” within, an automated machine’s safety door or fencing can’t think for itself. You have to be the “plug” and the “software” that acts as the machine’s safety solution.
Consider the common reality of each material and design choice, and don’t rely on initial promise or material misconceptions to sway your decision.
Match your materials and methods to your machine’s environment so your safety enclosure meets its operators’ needs.
What are crop packaging robots’ main applications?
The applications of crop packaging robots extend across various facets of agriculture, enhancing:
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- Efficiency
- Productivity
- Accuracy
Here are some prominent areas where these robots find their utility:
Fruit and vegetable packaging
These robots play a vital role in packaging fresh produce such as:
- Apples
- Oranges
- Tomatoes
- Strawberries
They handle the produce gently to prevent damage, sort them based on predefined parameters like size, color, and quality, and then package them for distribution. These robots benefit agriculture by offering high-speed operations and reducing labor-intensive tasks.
Grain packaging
Crop packaging robots find important applications in grain packaging. Here, they automate the process of filling and sealing bags of grains such as wheat, corn, or rice. They can manage substantial volumes, operating round the clock, ensuring minimal downtime and maximum productivity.
Dairy product packaging
In the dairy industry, crop packaging robots package products like cheese and butter. Robots handle moving finished products into crates and boxes. These machines offer high accuracy, speed, and efficiency in dairy product packaging, ensuring product integrity and quality.
Post-harvest crop handling
Automated post-harvest handling includes crops like:
- Potatoes
- Onions
- Carrots
- Radishes
Crop packaging robots can sort, grade, and package these crops efficiently. This leads to a reduction in crop losses and improves overall yield.
In summary, the applications of crop packaging robots are diverse and span various sub-sectors within agriculture. By automating packaging tasks, these robots help farms:
- Enhance productivity
- Minimize waste
- Reduce labor costs
- Increase overall efficiency
What types or crop packaging robot exist?
Crop packaging robots are quite varied in their designs and functionalities. This diversity is key for addressing the unique needs of different agricultural tasks. The different types of crop packaging robots can broadly be categorized based on their operation method, task specificity, and mechanical construction. Here are some prominent types:
Six-axis robots
Six-axis robots have emerged as a transformative tool in the agricultural sector, specifically in the arena of crop picking. These robots, characterized by their six degrees of freedom, can replicate the complex movements of a human arm. This makes them highly adept at navigating intricate environments.
For instance, in a fruit orchard, a six-axis robot can extend, rotate, and maneuver its arm to pick fruits that might be nestled amid dense foliage. These robots do so without causing damage to the tree or the fruit. The robot's high degree of precision and gentle handling helps maintain the quality of the produce, reducing crop loss due to bruising or dropping.
Collaborative robots (cobots)
These robots look very similar to six-axis robots. However, a key differentiator for cobots is that they are designed to work alongside humans in shared workspaces. Cobots can assist people in tasks like packaging and palletizing. They are built to be safer than industrial robots, flexible, and easy to program.
Custom-built robots
Some applications may require highly specific functionality that isn't covered by standard robot designs. In these cases, custom robots are built to cater to specific needs. For example, the handling of young nursery plants requires special tools and specific capabilities that standard robot types aren’t optimized for. Using specialized technology enables farmers to maximize the performance of their automation systems for a particular task.
Each of these types serves different purposes and can significantly enhance crop packaging operations' efficiency, accuracy, and productivity. The choice of robot type depends on the specific needs of the agricultural process in question. Common factors to consider when selecting a robot include:
- Type of crop
- Scale of operations
- Level of precision required
- Reach requirements
- Payload requirements
Advantages of crop picking robots
Integrating crop packaging robots into agricultural operations has brought numerous advantages that benefit the industry.
Increased efficiency and productivity
Crop packaging robots can operate continuously at a consistent and efficient pace. This significantly boosts productivity levels compared to manual labor. The around-the-clock operation capabilities of these machines lead to a dramatic increase in the throughput of packaging operations.
Reduced labor costs
The use of crop picking robots handles a significant portion of the post-harvesting process. This results in reduced applied labor costs. This is particularly beneficial in regions where agricultural labor is scarce or expensive.
Improved quality and consistency
Robots ensure a high level of precision and consistency in packaging, thereby improving the quality of output. Machine vision enables these robots to sort and package crops based on exact parameters, resulting in consistently high-quality packaged goods.
Reduced waste and damage
Robots can handle crops gently, reducing damage and waste. This is particularly crucial for delicate produce such as fruits and vegetables, where manual handling can often lead to bruising or other damage.
In-house packaging process
Deploying crop packaging robots allows agricultural companies to bring the packaging process in-house, moving away from reliance on external services. This allows for greater control over the packaging process, resulting in improved quality and timeliness.
For instance, a farm that grows and packages its own produce can ensure that only the freshest items are packaged immediately after they're picked. This also allows for quicker adjustments to packaging parameters as market demands shift.
What are the limitations?
While crop packaging robots provide numerous benefits, there are also certain limitations to consider:
High initial investment
The procurement and set-up of advanced crop packaging robots can be expensive, often running into tens of thousands to hundreds of thousands of dollars depending on the complexity and capability of the machine.
For smaller or marginally profitable agricultural businesses, such a hefty initial investment may be challenging to justify, especially given the unpredictability of agricultural returns. However, many farms are finding significant returns for the right application and successful integration.
Technical expertise required
These machines are complex and require operators with technical training for optimal performance. Additionally, the maintenance and repair of these robots often demand specialized personnel.
For businesses in remote agricultural regions, gaining access to such skilled technicians can be a challenge. Also, any downtime due to malfunctioning robots can significantly impact productivity. Agricultural companies should have a plan or resources to support their equipment.
Lack of adaptability
Crop packaging robots perform exceptionally well in structured, consistent environments, but their performance may decline when faced with unexpected changes or variability in their work environment.
For instance, they might struggle if there are significant variations in crop sizes, shapes, colors, or conditions. They are designed to perform specific tasks and may not adapt well to unusual circumstances or non-standard packaging requirements without changes in their programming.
Market size potential for crop packaging robots
The market size of automation in agriculture has experienced a significant surge, presenting immense growth opportunities for the industry. In , the Agriculture Robots Market was valued at USD 7.07 billion, and this figure is projected to skyrocket to USD 24 billion by the year , boasting a remarkable Compound Annual Growth Rate (CAGR) of 15.4% during the forecast period from to .
This exponential growth can be attributed to the increasing adoption of cutting-edge technologies, such as crop packaging robots, which have revolutionized the agricultural landscape.
Last thoughts
Crop packaging robots are ushering in a new era of efficiency and precision in the agricultural industry. Despite the significant benefits, a clear understanding of their limitations is necessary to achieve a successful crop packaging robot integration. With ongoing technological advancements, these limitations are likely to be progressively mitigated.
It's clear that the future of agricultural packaging lies in the continued integration of robotic technology. As businesses navigate this evolving landscape, the key will be understanding how to apply robots to their crop packaging processes and mitigate their limitations. In doing so, the potential for increased productivity, cost savings, and overall process improvement is immense, setting the stage for a more sustainable and profitable agricultural industry.
What’s next?
You may be ready to take the next step toward automating your harvesting process, but where do you start?
The HowToRobot platform connects buyers of automation with a variety of suppliers in a streamlined, easy-to-use environment.
Post your project on HowToRobot today for free, and begin receiving offers from vetted and relevant automation vendors from our supplier network.
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