Robotics and Artificial Intelligence – Part 2- Manufacturing Applications

Introduction

A Robot is a programmable, multi-functional, machine designed to perform complex tasks with a degree of autonomy when required.

Artificial Intelligence (AI) is technology that enables computers and machines to simulate human learning, comprehension, problem solving, decision making, creativity and autonomy, which can provide responses to the information provided.

Manufacturing covers a huge number of different Products from Automobiles to Toys, but they all have measure of Automation, Robotics and Artificial Intelligence (AI) Applications. However one thing is clear that the greater the use of these technologies the more it has an impact on the Human Workforce. In addition, the Integrated Automation and Control systems of Factories from Raw Materials to the Finished Products is Increasing Output whilst Reducing the Work force. It is impossible to cover all of the different Manufacturing of Products, using of Robotics and Artificial. This article will look at some of the different Robots and their uses in the Factory. We will look at Automobile Manufacturing which is the most recognisable use of Robots and the Electronic Systems Manufacturing.

Manufacturing – Process

When you consider a Manufacturing Process, it is made up from all the different Activities necessary to create the Final Product. There is a considerable number of Activities which need to be undertaken in the Correct Order; at the Correct Time; in the Correct Manner; to the Correct Standard; Examined and Tested; Quality Control Checks; Packaged and Delivered. Today many of these Activities are undertaken by a Combination of Humans, Robotics and AI.

Automobile Manufacturing

My own experience of Automotive Manufacturing was in 1990 as the owner of a Computer Based Training (CBT) company, when I visited to discuss the possibility of Designing and Developing CBT for the Maintenance of the Robotic Systems, at the Japanese Automobile Factory in Sunderland, England.

Today the Smart Factory uses Autonomous Robots in this case as part of the Vehicle Bodywork Assembly and Welding Production Line, which is continually monitored by the Smart Factory System, using Robot Sensors and a Network Systems and Artificial Intelligence, referred to as the ‘Internet of Things’ (IoT). This is a a BMW Factory Production Line in Leipzig Germany. You will note that the Robots Design is far more complex than the 1990’s Robots, however, they provide the Dexterity and Speed required to access difficult areas of the Bodywork.

After the Bodywork is completed the Smart Factory again uses Specially Designed Autonomous Robots with many types of Sensors to Inspect the Integrity of the Weld Seams and other parts of the Bodywork. The Data of the Inspection is Transferred to the ‘IoT’ for Analysis and further action if required.

After the Bodywork is completed and has been Inspected for the Integrity of the Weld Seams and other parts of the Bodywork it is ready for Painting. Again this is undertake by Autonomous Robots specially designed to provide the Correct Amount of Paint over the whole Vehicle and a Colour which is controlled by the ‘Internet of Things’ based upon the specific Vehicle Bodywork Number and other Data. After the Completion of Painting the Data is again Transferred to the ‘IoT’ and the Vehicle is moved onto the next Activity.

Another process, Windscreen fitment is also completed by a Robot alone or in some cases with Humans ensuring the final stage of Windscreen placement is correct. The advantage of the Robot is that it applies the sealant perfectly in terms of quantity and accuracy. Normally this type of Robot is autonomous and part of the production line which is controlled by the IoT.

In some cases, especially Commercial Vehicles, there are Robots that Select the Vehicles Doors from the adjacent racks and the Fit them to the Cabin. They use Cameras and other Proximity Sensors aided by AI Software to guide the Robot to the correct position and attach them using the specified Bolts.

The Automobile Manufacturing process for all types of Vehicles large and small, Fossil Fuel, Hybrids and Electrical use a significant amount of Robotics and Artificial Intelligence combined with the ‘Internet of Things in all parts of the world. We have just seen only some of the Robotics involved in the Automobile Manufacturing Cycle which contributes to the high output and quality of Vehicle Manufacturing.

Electronic Systems Manufacturing

Today another extremely important Manufacturing process is creation of the Electronic Systems for almost all Electrically Operated Systems, from a Television (TV) to the most advanced Aircraft Avionics Systems.

The Electronic Control Systems are created by the use of a number of Electronic, Printed Circuit Board Assemblies (PCBA’s). These start as a Printed Circuit Board (PCB), which is then Populated with the Electronic Components that create a PCBA Functional Electronic System. The image below shows a simple PCB (left) and the resultant PCBA (right). With a simple PCBA shown below this could be done by a Human using a Soldering Iron to melt the Solder and apply it to the Metal Terminals to the Copper Circuit.

The more Complex PCB used for Surface-mounted Technology (SMT), Electronic Components has the Electrical Circuit already etched on the PCB connected with the ‘Shoulder Pads’ to which the Electronic Components are connected.

From the Complex PCB shown above the Electronic Components can now be attached to the PCB creating the Complex PCBA. A typical example is shown below.

Creating a PCBA such as the one shown above is a complex, precision and delicate process, especially when Picking and Handling the Electronic Components, Placing them in the Correct Position and then Soldering them to the PCB. Today the majority of Electronic Components are Integrated Circuits in an Encased Microchip (Square and Oblong Black Components) shown below. There is also other much Smaller Components that also have to be attached to the PCB. Today most PCBA’s use Surface-mount-Technology (SMT) which means that the Components are placed on the Surface of the PCB which have ‘Shoulder Pads’ that are covered with Sticky, Solder Paste (Solder and Gel like Flux) and are connected to the Electronic Circuit.

The first stage is that a Specific Identical Set Blank PCB’s that have ‘Shoulder Pads’ and ‘Soldering Paste’ are placed on a Production Line by a Robot. The first Robots are the ‘Pick and Place’ (PnP) which are preprogrammed for this set of PCB’s and have access to the required Components to make the PCBA. These are smaller ‘Table Mounted Robot Arms’ that some have small ‘Vacuum Nozzles’ for the smaller Components and a ‘Pick-up Mechanism’ for the larger Microchips. The Robots select the Components and then place them on the respective ‘Shoulder Pads’ on the PCB. These Robots can PnP tens of thousands of Components per hour with accuracy and precision.

This is another type of Electronic PCBA PnP System with Internal Robotics that is Computer Controlled using AI software.

After all of the Components have been placed in the Correct Position on the PCBA it is then transferred to a ‘Reflow Soldering Oven’ which provides sufficient heat to activate the Soldering Paste which Solders the Components to the SMT Shoulder Pads.

After the PCBA has passed through the Reflow Soldering Oven it then goes via a Automated Optical Inspection (AOI) System that Inspects the PCBA for any defects using a specialised Camera and Artificial intelligence Software. Any defects are normally rectified by a Human.

Once they pass the Inspection the PCBA’s are Stacked ready for Testing.

There are two types of Automated Testing, In-circuit Testing and Quality Control and Flying Probe Testing where the Probes are positioned automatically to the points on the PCBA that should provide the correct reading for each of the points. These are Preprogrammed Robotics for the Specific types of PCBA’s.

After testing the the PCBA’s are Packaged. PCBA’s are very Sensitive to Static Electricity and Moisture therefore each PCBA is Hermetically Sealed in a Anti-Static, Vacuum Sealed Bag.

Each of the Sealed PCBA’s surrounded in bubble wrap and are then packed in Cardboard Boxes in this case by Robots for shipment.

Conclusion

We have just discussed only two of many Manufacturing Applications but the use of Robotics and Artificial Intelligence (AI) Software is used extensively for Manufacturing and Management of Processes in terms of Internet of Things (IoT). It is also noticeable that the use Robotics and AI is increasing which is decreasing the need for Human involvement. Although we have not discussed this but Humanoids are being Manufactured in China in their hundreds to undertake even more of a role replacing the Humans. Below is the trial of Chinese made Humanoids in a Factory. There will be many more to come.

Without a doubt the Robotics and Artificial Intelligence is here to stay and are having a major positive impact on many Manufacturing Industries. However, in doing so it is also having a negative impact on the increasing number of Humans that require work to provide the income for their families. This also applies to the next ‘Robotics and Artificial Intelligence – Part 3 – Service Applications’.