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Waterways: the Many Routes of Water Detection

 

Water is everywhere, in most things living and not, and the amount of this precious resource is always important. The simplest form of monitoring water is if it is there or not. In your body, you feel the effects of dehydration, in your car the motor overheats, and on your lawn, you see the dryness of the grass. What about your specialty machine or your assembly process? Water and other liquids are inherently clear so how do you see them, especially small amounts of it possibly stored in a tank or moving fast? Well, there are several correct answers to that question. Let’s dive into this slippery topic together, pun intended.

While mechanical float and flow switches have been around the longest, capacitive, photoelectric, and ultrasonic sensors are the most modern forms of electronic water detection. These three sensing technologies all have their strong points. Let’s cover a few comparisons that might help you find your path to the best solution for your application.

Capacitive sensors

Capacitive sensors are designed to detect nonferrous materials, but really anything that can break the capacitive field the sensor creates, including water, can do this. This technology allows for adjustment to the threshold of what it takes to break this field. These sensors are a great solution for through tank level detection and direct-contact sensing.

Ultrasonic sensors

Want to view your level from above? Ultrasonic sensors give you that view. They use sound to bounce off the media and return to the sensor, calculating the time it takes to measure distance. Their strong point is that they can overcome foam and can bounce off the water where light struggles when there is a large distance from the target to the receiver. Using the liquid from above, ultrasonics can monitor large tanks without contact.

Photoelectric sensors

Use photoelectric sensors when you’re looking at a solution for small scale. Now, this might require a site tube if you are monitoring the level on a large tank, however, if you want to detect small amounts of water or even bubbles within that water, photoelectric sensors are ideal. Using optical head remote photoelectric sensors tied to an amplifier, the detail and speed are unmatched. Photoelectric sensors are also great at detecting liquid levels on transparent bottles. In these applications with short distances, you need speed. Photoelectric sensors are as fast as light.

So, have you made up your mind yet? No matter which technology you choose, you will have a sensor that gives you accurate detail and digital outputs and is easy on the budget. Capacitive, ultrasonic, and photoelectric sensors provide all this and they grow with your application with adjustability.

Liquids are everywhere and not going away in manufacturing. They will continue to be an important resource for manufacturing.  Cherish them and ensure you account for every drop.

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On the Level: Selecting the Right Sensor for Level Detection

We’ve probably all experienced having the “pot boil over” or “run dry” at one time or another. The same is frequently true on a much larger scale with many industrial processes. These large events can prove costly whether running dry or overflowing, resulting in lost product, lost production time, damage to the tank, or even operator injury. And then there is the cleanup!

The fact is, many procedures require the operator to monitor the bin or tank level – especially on older equipment. This human factor is prone to fail due to inattention, distractions, and lack of proper training. With today’s employee turnover and the brain drain of retirements, we need to help the operators out.

Multiple solutions exist that can provide operators with sufficient warning of the tank and bin levels being either too low or too high. This article provides a framework and checklist to guide the selection of the best technology for a specific application.

What type of monitoring is necessary?

First, consider whether the application requires or would benefit from continuous monitoring, or is point-level monitoring all that is needed?

    • Point-level monitoring is the simplest. It is essentially sensing whether the product is present at specific detection point(s) in the tank or bin. If the goal is to avoid running dry or overflowing, monitoring the bin or tank point level may be all that is required. Point-level sensors typically are best if the product levels can be detected through the wall or inside the tank or bin itself. A number of sensors can prevent false readings with products that are viscous, leaving residue on the sensor, and even ignore foam.
    • Continuous-level monitoring detects levels along a range – from full to empty. This is required when the exact level of the product must be known, such as for batch mixing.

Checklist for sensor selection

The checklist below can help guide you to what should be the appropriate technologies to consider for your particular application. Frequently, more than one type of technology may work, given the media (or product) you’re detecting, so it may make sense to test more than one.

Checklist for sensor selection

Ultimately, the sensor(s) you select must reliably sense/detect the presence of the subject product (or media). Which solution is least costly is frequently a big consideration, but remember there can be a hefty cost associated with a sensor that gives a false reading to the operator or control system.

Choosing sensors for washdown or clean-in-place environments

For products that will be consumed or entered into the human body, further selection considerations may include sensors that must survive in washdown or clean-in-place environments without contaminating the product.

The encouraging news is that sensors exist for most applications to detect product levels reliably. The finesse is in selecting the best for a given application when multiple technologies can do the job.

Again, there may be some trial and error at play but this checklist should at least narrow the field and pointed you to the better solution/technology.

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Using Guided Format Change to Improve Changeover and Productivity

Long before Covid, we were seeing an increase in the number of packaging SKUs. In 2019, Packaging Digest reported an estimated 42% increase in SKUs in the food and beverage industry.

Since Covid, there has been a further explosion of new packaging sizes, especially in the food and beverage marketplace. Food manufacturers have gotten very creative. Instead of raising prices due to the higher costs of goods, for example, they can reduce the size of product packages while keeping the consumer prices the same.

Many of today’s production machines are not equipped to changeover as quickly and as accurately to meet the demand of the marketplace. Manufacturers now face the challenge of “semi-automating” their existing machines, as opposed to procuring new machines or adding expensive motors to existing machines. One solution is to digitalize change points on existing machines.

Companies are looking to reduce the amount of time and the mistakes that occur when doing product changeovers. Allowing for operator guidance and position measurement can reduce your time and enhance your accuracy of those changeover events. Measurements are then tied to the recipe and the operator becomes the prime mover.

Guided Format Change

There are lots of technologies out there for helping with guided format change, such as automated position measurement, machine position, distance measurement, linear measurement, and digitalized rotary encoders.


As you are likely quite aware, there are often scales, marks, etc., written onto machines that don’t provide the greatest degree of accuracy. Introducing digitalized position and distance sensing can help you reduce time and limit errors during changeovers.

Change Part Identification

The other side of changeover is change part identification. Quite often during this process parts on the machine must be exchanged. Using the wrong change part can result in mistakes, waste, and delays, and can even damage existing machines.

Technologies, such as RFID, can help ensure the correct change part is chosen and added to the machine. During a recipe change, the operator can then validate that all the correct parts are installed before the startup of the next product run.

Guided format change is a cost-effective way to reduce changeover time and increase productivity either by retrofitting your existing machines or even new machines.

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Sensor Mounting Made Easy

So, you’ve figured out the best way to detect the product shuttle paddle in your cartoning/packaging machine needs a visible red laser distance sensor. It’s taken some time to validate that this is the right sensor and it will be a reliable, long-term solution.

But then you realize there are some mechanical issues involved with the sensor’s placement and positioning that will require a bit of customization to mount it in the optimal location. Now things may have just become complicated. If you can’t design the additional mounting parts yourself, you’ll have to find someone who can. And then you have to deal with the fabrication side. This all takes time and more effort than just buying the sensor.

Or does it?

Off-the-shelf solutions

It doesn’t have to be that complex. There are possible off-the-self solutions you can consider that will make this critical step of providing a reliable mounting solution – possibly as straightforward as choosing the right sensor. Multiple companies offer sensor mounting systems that accommodate standard sensor brackets. Over the years, companies have continued to develop new mounting brackets for many of their sensor products, from photoelectric sensors and reflectors to proximity sensors to even RFID heads and linear transducers.

So it’s only natural to take that one step further and create a mounting apparatus and system that not only provides a mounting bracket, but also a stable platform that incorporates the device’s mounting bracket with things like stand-off posts, adjustable connection joints, and mounting bases. Such a flexible and extensive system can solve mounting challenges with parts you can purchase, instead of having to fabricate.

Imagine in the example above you need to mount the laser distance sensor off the machine’s base and offset it in a way that doesn’t interfere with the other moving parts of the cartoner. Think of these mounting systems and parts as a kind of Erector Set for sensing devices. You can piece together the required mounting bracket with a set of brace or extension rods and a mounting base that raises the sensor up and off the machine base and even angles it to allow for pointing at the target in the most optimal way.

The following are some mounting solutions for a variety of sensors:

These represent only a small number of different ways to mix and match sensor device brackets and mounting components to find a solid, reliable and off-the-shelf mounting solution for your next mounting challenge. So before considering the customization route, next time take a look at what might already be out there for vendors. It could make your life a lot simpler.

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Looking Into & Through Transparent Material With Photoelectric Sensors

Advance automated manufacturing relies on sensor equipment to ensure each step of the process is done correctly, reliably, and effectively. For many standard applications, inductive, capacitive, or basic photoelectric sensors can do a fine job of monitoring and maintaining the automated manufacturing process. However, when transparent materials are the target, you need a different type of sensor, and maybe even need to think differently about how you will use it.

What are transparent materials?

When I think of transparent materials, water, glass, plexiglass, polymers, soaps, cooling agents, and packaging all come to mind. Because transparent material absorbs very little of the emitted red LED light, standard photoelectric sensors struggle on this type of application. If light can make its way back to the receiver, how can you tell if the beam was broken or not? By measuring the amount of light returned, instead of just if it is there or not, we can detect a transparent material and learn how transparent it is.

Imagine being able to determine proper mixes or thicknesses of liquid based on a transparency scale associated to a value of returned light. Another application that I believe a transparent material photoelectric senor would be ideal for is the thickness of a clear bottle. Imagine the wall thickness being crucial to the integrity of the bottle. Again, we would measure the amount of light allowed back to the receiver instead of an expensive measurement laser or even worse, a time-draining manual caliper.

Transparent material sensor vs. standard photoelectric sensor

So how does a transparent material sensor differ from a standard photoelectric sensor? Usually, the type of light is key. UV light is absorbed much greater than other wavelengths, like red or blue LEDs you find in standard photoelectric sensors. To add another level, you polarize that UV light to better control the light back into the receiver. Polarized UV light with a polarized reflector is the best combination. This can be done on a large or micro scale based on the sensor head size and build.

Uses for transparent material sensor include packaging trays, level tubes, medical tests, adhesive extrusion, and bottle fill levels, just to name a few. Transparent materials are everywhere, and the technology has matured. Make sure you are looking into specialized sensor technologies and working through best set-up practices to ensure reliable detection of transparent materials.

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Condition Monitoring & Predictive Maintenance: Addressing Key Topics in Packaging

A recent study by the Packaging Machinery Manufacturers Institute (PMMI) and Interact Analysis takes a close look at packaging industry interest and needs for Condition Monitoring and Predictive Maintenance. Customer feedback reveals interesting data on packaging process pain points and the types of machines and components which are best monitored, the data which should be gathered, current maintenance approaches, and the opportunity for a better way: Condition Monitoring and Predictive Maintenance.

What keeps customers awake at night?

The PMMI survey indicates that form, fill & seal machines are very critical to packaging processes and more likely to fail than many other machines. Also critical to the process and a common failure point are filling & dosing machines, and labeling machines.

These three categories of machines are in use in primary packaging and are often the key components in the production line; the downstream processes are usually less critical. They often process a lot of perishable products at high speeds, therefore, any downtime is a big problem for overall equipment effectiveness (OEE), quality, and profitability.

In terms of the components on these machines that are most likely to fail, the ones are pneumatic systems, gearboxes, motors/drives, and sensors.

How can customers reduce unplanned downtime and improve OEE?

Our data shows that the top customer issue is unplanned machine breakdowns, but many packaging firms use reactive or preventative maintenance approaches, which may not be effective for most failures. An ARC study found that only about 20% of failures are age-related. The 80% of failures that are non-age-related would likely not be addressed by reactive or preventative maintenance programs.

A better way to address these potential failures is to monitor the condition of critical machines and components. Condition monitoring can provide early detection of machine deterioration or impending failure and the data can be used for predictive maintenance. Many “smart sensors” can now measure vibration, temperature, humidity, pressure, flow, inclination, and many other attributes which may be helpful in notifying users of emerging problems. And some of these “smart sensors” can also “self-monitor” and help alert users to potential failures in the sensor itself.

What are packaging customers actually doing?

The good news is that the packaging industry is moving forward to find a better way and users understand that Condition Monitoring/Predictive Maintenance gives them the opportunity to prevent unplanned failures, reduce unplanned downtime, and improve OEE, quality and profitability. About 25% of customers have already implemented some sort of Condition Monitoring / Predictive Maintenance, while about 20% are piloting it and 30% plan to implement it. This means that 75% of customers are very interested in Condition Monitoring/Predictive Maintenance, by far the most interest in any technology discussed in the PMMI survey.

Where do you start?

    • Look for the machines which cause you the most frustration. PMMI identified form, fill & seal, filling & dosing, and labeling machines, but there are other machines, including bottling, cartoning, and case/tray handling, that could fail and cause production downtime or damaged product.
    • Consider where, when, and how equipment can fail. Look to your own experience, ask partners with similar machines or perhaps the equipment supplier to help you determine the most common failure points and modes.
    • Analyze which parts of the machine fail. Moving parts are usually the highest potential failure point. On packaging machines, these include motors, gearboxes, fans, pumps, bearings, conveyors, and shafts.
    • Consider what to measure. Vibration is common, and often assessed in combination with temperature and humidity. On some machines, pressure, flow, or amperage/voltage should be measured.
    • Determine the most appropriate maintenance program for each machine. Consider the costs/benefits of reactive, preventative, condition-based monitoring or predictive approaches. In some cases, it may be OK to let a non-critical, low-value asset “run-to-failure,” while in other cases it might be worth investing in Condition Monitoring or Predictive Maintenance to prevent a critical machine’s costly failure.
    • Start small by implementing condition monitoring on one or two machines, and then scaling up once you’ve learned what does and doesn’t work. Using a low-cost sensor, which can be easily integrated with existing controls architectures or added on externally, is also a great way to start.

Condition Monitoring and Predictive Maintenance offer packaging firms a “better way” to address key topics including machine downtime, failures, and OEE. Users can move from a reactive to a proactive maintenance approach by monitoring attributes such as vibration and temperature on critical machines and then analyzing the data. This will allow them to detect and predict potential failures before they become critical, and thereby, reduce unplanned downtime, improve OEE, and save money.

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Why Use Ultrasonic Sensors?

by Nick Smith

When choosing what sensor to use in different applications, it is important to first look at how they operate. Capacitive sensors generate an electrical field that can detect various liquids or other materials, such as glass, wood, paper, ceramic, and more at a close. Photoelectric sensors emit a light beam that is either received by a light sensor or bounced back to the emitter to detect an object’s presence or measure the distance to an object. Ultrasonic sensors bounce a sound wave off objects to detect them, which can make them a good solution for a surprising variety of uses.

How ultrasonic sensors operate

Ultrasonic sensors operate by emitting an ultra-high frequency sound wave that ranges from 300 MHz to 3 GHz, which is well above the 15-17 kHz range that humans can hear that bounces off the target object. The sensor measures the amount of time that sound wave takes to return to calculate the distance to the object. Ultrasonic sensors send these sound waves in a wider beam than a photoelectric uses, so they can more easily detect objects in a dusty or dirty environment. And with a greater sensing distance than capacitive sensors, they can be installed at a safe distance and still function effectively

Common applications for ultrasonic sensors

These capabilities together make ultrasonic sensors a great choice for tasks like detecting fill level, stack height and object presence. Sound waves are unaffected by the color, transparency, or consistency of an object or liquid, which makes it an obvious contender in the packaging, food, and beverage industry and many other industries with similar manufacturing processes.

So to monitor glass bottles as they travel on a conveyor, an ultrasonic sensor could be a good choice. These sensors will consistently work well detecting clear or reflective materials such as water, paint, glass, etc., which can cause difficulties for photoelectric sensors. Another benefit of these sensors is the ability to mount them further away from their targets. For example, there are ultrasonics that can be mounted between 20 to 8000 mm away from the object. After tuning your setup, you can detect very small objects as easily as larger, more visible items.

Another common application for ultrasonic sensors is monitoring boxes. Properly implemented ultrasonic sensors can detect different sizes of boxes as they travel on a conveyor belt by constantly emitting and receiving sound waves. This means that each box or object will be measured by the sound wave. Different photoelectric and capacitive sensors may fail to detect the full presence of an object and may only be able to detect a specific point on an object.

When it comes to all types of different fill-level applications, there are many ways a sensor can monitor various liquids and solids. The width of an ultrasonic beam can be increased to detect a wider area of solid material in a hopper or decreased to give a precise measurement on liquid levels. This ability to detect a smaller or larger surface area gives the user more utility when deciding how to meet the requirements of an application. Although capacitive sensors can detect fill levels very precisely as well, factors like beam width and sensing distance might make ultrasonic a better choice.

With so many different sensor technologies available and factors like target material and sensing distance being such important factors, choosing the best sensor for an application can be demanding. A trusted expert who is familiar with these different technologies and the factors related to your applications and materials can help you confidently move toward the smart factory of the future.

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The 5 Most Common Types of Fixed Industrial Robots

The International Federation of Robotics (IFR) defines five types of fixed industrial robots: Cartesian/Gantry, SCARA, Articulated, Parallel/Delta and Cylindrical (mobile robots are not included in the “fixed” robot category). These types are generally classified by their mechanical structure, which dictates the ways they can move.

Based on the current market situation and trends, we have modified this list by removing Cylindrical robots and adding Power & Force Limited Collaborative robots. Cylindrical robots have a small, declining share of the market and some industry analysts predict that they will be completely replaced by SCARA robots, which can cover similar applications at higher speed and performance. On the other hand, use of collaborative robots has grown rapidly since their first commercial sale by Universal Robots in 2008. This is why collaborative robots are on our list and cylindrical/spherical robots are not.

Therefore, our list of the top five industrial robot types includes:

    • Articulated
    • Cartesian/Gantry
    • Parallel/Delta
    • SCARA
    • Power & Force Limited Collaborative robots

These five common types of robots have emerged to address different applications, though there is now some overlap in the applications they serve. And range of industries where they are used is now very wide. The IFR’s 2021 report ranks electronics/electrical, automotive, metal & machinery, plastic and chemical products and food as the industries most commonly using fixed industrial robots. And the top applications identified in the report are material/parts handling and machine loading/unloading, welding, assembling, cleanrooms, dispensing/painting and processing/machining.

Articulated robots

Articulated robots most closely resemble a human arm and have multiple rotary joints–the most common versions have six axes. These can be large, powerful robots, capable of moving heavy loads precisely at moderate speeds. Smaller versions are available for precise movement of lighter loads. These robots have the largest market share (≈60%) and are growing between 5–10% per year.

Articulated robots are used across many industries and applications. Automotive has the biggest user base, but they are also used in other industries such as packaging, metalworking, plastics and electronics. Applications include material & parts handling (including machine loading & unloading, picking & placing and palletizing), assembling (ranging from small to large parts), welding, painting, and processing (machining, grinding, polishing).

SCARA robots

A SCARA robot is a “Selective Compliance Assembly Robot Arm,” also known as a “Selective Compliance Articulated Robot Arm.” They are compliant in the X-Y direction but rigid in the Z direction. These robots are fairly common, with around 15% market share and a 5-10% per year growth rate.

SCARA robots are most often applied in the Life Sciences, Semiconductor and Electronics industries. They are used in applications requiring high speed and high accuracy such as assembling, handling or picking & placing of lightweight parts, but also in 3D printing and dispensing.

Cartesian/Gantry robots

Cartesian robots, also known as gantry or linear robots, move along multiple linear axes. Since these axes are very rigid, they can precisely move heavy payloads, though this also means they require a lot of space. They have about 15% market share and a 5-10% per year growth rate.

Cartesian robots are often used in handling, loading/unloading, sorting & storing and picking & placing applications, but also in welding, assembling and machining. Industries using these robots include automotive, packaging, food & beverage, aerospace, heavy engineering and semiconductor.

Delta/Parallel robots

Delta robots (also known as parallel robots) are lightweight, high-speed robots, usually for fast handling of small and lightweight products or parts. They have a unique configuration with three or four lightweight arms arranged in parallelograms. These robots have 5% market share and a 3–5% growth rate.

They are often used in food or small part handling and/or packaging. Typical applications are assembling, picking & placing and packaging. Industries include food & beverage, cosmetics, packaging, electronics/ semiconductor, consumer goods, pharmaceutical and medical.

Power & Force Limiting Collaborative robots

We add the term “Power & Force Limiting” to our Collaborative robot category because the standards actually define four collaborative robot application modes, and we want to focus on this, the most well-known mode. Click here to read a blog on the different collaborative modes. Power & Force Limiting robots include models from Universal Robots, the FANUC CR green robots and the YuMi from ABB. Collaborative robots have become popular due to their ease of use, flexibility and “built-in” safety and ability to be used in close proximity to humans. They are most often an articulated robot with special features to limit power and force exerted by the axes to allow close, safe operation near humans or other machines. Larger, faster and stronger robots can also be used in collaborative applications with the addition of safety sensors and special programming.

Power & Force Limiting Collaborative robots have about 5% market share and sales are growing rapidly at 20%+ per year. They are a big success with small and mid-size enterprises, but also with more traditional robot users in a very broad range of industries including automotive and electronics. Typical applications include machine loading/unloading, assembling, handling, dispensing, picking & placing, palletizing, and welding.

Summary­

The robot market is one of the most rapidly growing segments of the industrial automation industry. The need for more automation and robots is driven by factors such as supply chain issues, changing workforce, cost pressures, digitalization and mass customization (highly flexible manufacturing). A broad range of robot types, capabilities and price points have emerged to address these factors and satisfy the needs of applications and industries ranging from automotive to food & beverage to life sciences.

Note: Market share and growth rate estimates in this blog are based on public data published by the International Federation of Robotics, Loup Ventures, NIST and Interact Analysis.

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Protecting photoelectric and capacitive sensors

Supply chain and labor shortages are putting extra pressure on automation solutions to keep manufacturing lines running. Even though sensors are designed to work in harsh environments, one good knock can put a sensor out of alignment or even out of condition. Keep reading for tips on ways to protect photoelectric and capacitive sensors.

Mounting solutions for photoelectric sensors

Photoelectric sensors are sensitive to environmental factors that can cloud their view, like dust, debris, and splashing liquids, or damage them with physical impact. One of the best things to do from the beginning is to protect them by mounting them in locations that keep them out of harm’s way. Adjustable mounting solutions make it easier to set up sensors a little further away from the action. Mounts that can be adjusted on three axes like ball joints or rod-and-mount combinations should lock firmly into position so that vibration or weight will not cause sensors to move out of alignment. And mounting materials like stainless steel or plastic can be chosen to meet factors like temperature, accessibility, susceptibility to impact, and contact with other materials.

When using retroreflective sensors, reflectors and reflective foils need similar attention. Consider whether the application involves heat or chemicals that might contact reflectors. Reflectors come in versions, especially for use with red, white, infrared, and laser lights, or especially for polarized or non-polarized light. And there are mounting solutions for reflectors as well.

Considering the material and design of capacitive sensors

Capacitive sensors must also be protected based on their working environment, the material they detect, and where they are installed. Particularly, is the sensor in contact with the material it is sensing or not?

If there is contact, pay special attention to the sensor’s material and design. Foods, beverages, chemicals, viscous substances, powders, or bulk materials can degrade a sensor constructed of the wrong material. And to switch perspectives, a sensor can affect the quality of the material it contacts, like changing the taste of a food product. If resistance to chemicals is needed, housings made of stainless steel, PTFE, and PEEK are available.

While the sensor’s material is important to its functionality, the physical design of the sensor is also important. A working environment can involve washdown processes or hygienic requirements. If that is the case, the sensor’s design should allow water and cleaning agents to easily run off, while hygienic requirements demand that the sensor not have gaps or crevices where material may accumulate and harbor bacteria. Consider capacitive sensors that hold FDA, Ecolab, and CIP certifications to work safely in these conditions.

Non-contact capacitive sensors can have their own special set of requirements. They can detect material through the walls of a tank, depending on the tank wall’s material type and thickness. Plastic walls and non-metallic packaging present a smaller challenge. Different housing styles – flat cylindrical, discs, and block styles – have different sensing capabilities.

Newer capacitive technology is designed as an adhesive tape to measure the material inside a tank or vessel continuously. Available with stainless steel, plastic, or PTFF housing, it works particularly well when there is little space available to detect through a plastic or glass wall of 8mm or less. When installing the tape, the user can cut it with scissors to adjust the length.

Whatever the setting, environmental factors and installation factors can affect the functionality of photoelectric and capacitive sensors, sometimes bringing them to an untimely end. Details like mounting systems and sensor materials may not be the first requirements you look for, but they are important features that can extend the life of your sensors.

 

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Add Automation to Gain Safety and Control in Manufacturing

Industry automation not only has a positive effect on the improvement of production processes, it also significantly improves employee safety. New technologies can minimize the need for employees to work in dangerous situations by replacing them all together or by working cooperatively alongside them.

Overcoming fears of automation
Many workers fear technological progress due to the generally accepted view that robots will replace people in their workplaces. But their fears are conjecture. According to a study published in 2017 by scientists at the Universities of Oxford and Yale, AI experts predict a 50% chance of AI outperforming humans at all tasks within 45 years. But, instead of replacing all workers, there is a stronger chance AI will eliminate dangerous manual labor and evolve other roles. Following are a few examples.

    • Automation in palletizing systems
      Before automation-based solutions entered factories, laborers had to do most work by hand. A work system based on the strength of the human body, however, does not bring good results. Workers tire quickly, causing a decrease in their productivity. And with time, health problems related to regularly carrying heavy daily loads also begin to appear. Until recently, employees of the palletizing departments struggled with these problems. But today, robots are carrying out the work of moving, stacking, and transporting products on pallets.
    • Automation forging processes
      Also, until recently, forging processes in the metallurgical industry were performed with the help of human workers. There are still factories today in which blacksmiths are responsible for putting the hot metal element under the hammer to form the final shape of the product. Such a device hits with a force of several dozen tons, several times a minute. Being at the hammer is therefore extremely dangerous and may cause permanent damage to the worker’s health. Elevated temperatures in the workplace can also have negative effects on the body.

      At       most businesses, forging processes are now fully automated. Robots specially prepared for such work feed the elements to the automatic hammer with their grippers. And sensory solutions help make the job safer by detecting the presence of people or undesirable elements within the working machine. The quality control of manufactured products is also extremely important and more easily controlled with an automated system.
    • Automation in welding processes
      Welding processes are another dangerous activity in which automation is starting to play a key role. During welding work, toxic fumes are released from the gas lagging, which the welder regularly inhales. This can result in serious poisoning or chronic respiratory diseases. Welding also produces sparks which can lead to severe burns and worker blindness.

      Again, automation makes the process safer. High-class welding machines exist on the market that can work continuously, under human control. With such solutions, it is necessary to use appropriate protection systems to protect employees against possible contact with machines during work. Automation in this situation eliminates a dangerous role, and creates a new, safer, and, some would say, better work role.

Skillful design of automation systems
While factory automation eliminates some threats to workers, others often arise, creating the need for strict design plans prepared by specialists in this field. It is necessary to prepare the automation system in such a way that it not only ensures safety, it does so without reducing productivity or creating downtime which can cause the employee to bypass security systems. The systems blocking the working space of the machine should not interfere with the worker and the worker should not interfere with the system. Where possible, instead of a mechanical lock, an optical curtain at the feeding point should be used to stop the machine’s operation if a foreign object breaks the curtain’s beam of the light. Mechanical locks blocking access to the working space should be in places where it is not necessary to open the door frequently.

Successful human-machine collaboration
When designing automation systems in production companies, it is also necessary to remember that often a human is working alongside the robot. In palletizing systems, for example, a person is responsible for preparing the place for packing and cleaning the working area. For the work to go smoothly, it may be worth creating two positions next to each other. Mechanisms on the market today allow you to control the work of robots at a given position, assigning them to the workspace. Special security scanners prevent the robots from moving to positions where someone is working.