MEDICAL SUPPLIES AND PPE DURING COVID-19 · ROBOTIC CONTROL AND FAST DELIVERY
When the coronavirus pandemic struck: KM-Automation supplied the control systems for two robot cells, enabling the mass production of face shields for the Danish healthcare system – in record time.
The customer
The end customer is a Danish manufacturer which, during the COVID-19 pandemic, secured a contract for 1.5–2 million face shields for the hospital sector. Production was initially manual, with operators assembling the visors by hand. Production volumes were far from keeping pace with demand, and the delivery schedule was under pressure – whilst the end customer had no previous experience with automated systems.
The task
There was an urgent need for an automated solution capable of assembling face shields at high speed and operable by staff with no technical background. The control system had to be simple and fault-tolerant, deliver at least 5 units per minute to meet the contract’s delivery schedule, and allow for future expansion with additional options – such as vision-based final inspection or extra label printers.
The technique
KM-Automation developed the control system for two identical robot cells based on a UR robot. The robot retrieves screen components from a magazine, whilst a label applicator and a Velcro feeder prepare the finished product. A conveyor belt with an encoder-controlled motor guides the finished visor out of the cell. The entire cycle is controlled via simple push-buttons and a visual status indicator, so that the operator can start, stop and reset the system after just a few seconds’ training. The system is CE-marked and features fault handling with a reset function, so that minor operational disruptions do not require a technician to be called out.
The dividend
Whereas production had previously been manual and inconsistent, the two cells now operated round the clock at a cycle time of 5 units per minute per cell. The contract with the hospital service was fulfilled, and operators without a technical background were able to operate the plant.