Copyright Douglas Publications, Inc. Fall 1998
Robotic Production Technologies (RPT) builds flexible turnkey robotic systems for manufacturing applications, primarily focused in the automotive trimming industry, and is a leader in water jet cutting technology in North America. At the end of last year, RPT looked seriously at lasers as an option for their clients when a company came to them with an unusual trimming need, and RPT determined their standard router or water jet processes would not serve.
"We had a client come to us with a special requirement to trim their products, and they needed a very clean, accurate cut. They wanted an automated cutting solution with an ease-of-part programming for trim line changes," said Chuck Russo, president of RPT. "We wanted to make sure we chose the correct solution for a flexible robotic system. We investigated using lasers in this particular application, and researched the different lasers available in the marketplace."
They had found that using trimming alternatives such as routers or water jet processes could result in the addition of two to three more secondary workers on the job per shift. With two to three shifts running per day at an annual pay range averaging $20,000 to $30,000 per person, that could cost a company over a million dollars per year. But because lasers give such a clean edge, an extra processing step to polish the trimmed pieces is not necessary.
"When we heard that the CO^sub 2^ lasers were available with higher wattage and stronger output capabilities, using a laser in this application became a viable option," said Doug Cicchini, RPT's technical director. "We talked with people in the industry, and when they recommended Synrad lasers, we decided to partner with them on this project."
Synrad, located in Mukileto, Wash., was founded in 1984 by Peter Laakman, who pioneered the RF-excited CO^sub 2^ laser. The company is a leader in the development and manufacture of innovative electro-optics and lasers for a multitude of industrial applications. It sells directly to a large number of OEMs, and also deals with system integrators who develop and build manufacturing cells for companies throughout the world.
To determine if the Synrad laser was indeed the best trimming device to install in their client's robotic system, RPT put the laser and prototype robotics system to the test. The company conducted cutting tests at their Automated Production Services division, where they run all their R&D prototype and production service tests for their customers.
"The challenge was to cut multiple pieces of automotive interior parts, and we actually looked at each of the three different trimming methods to determine their feasibility," said Russo. "We probably cut 300 sets of a thousand different parts for the company, and the Synrad laser gave us the cleanest edge. Because the laser's heat-affect zone is very minimal, it produces a very dean environment after the cutting process, and maintenance is minimal. That's significantly different than a water jet where you deal with water and debris cleanup."
The laser application in the prototype robotic system was so successful, said Russo, that the client ordered another laser "before we were done building the first one."
Impressed by this success, RPT is evaluating other projects with an eye to integrating CO^sub 2^ lasers into those robotic systems. As laser technology continues to improve and the wattage increases, RPT expects even more applications for it.
"We see a future in laser trimming applications. I think it's something our customers have a great interest in, and we're glad we can provide them with the option," asserted Russo. "It's an easy package to integrate, and will open up the door for other opportunities in the marketplace