Warehousing robotic maker turns to lubrication-free movement plastics

Robotic methods deployed in warehousing environments usually face demanding circumstances, corresponding to temperature fluctuations, the presence of mud, and fixed high-impact hundreds. Conventional steel machine elements — notably bearings that depend on exterior lubrication — are susceptible in these environments, resulting in extra frequent upkeep, downtime and potential contamination points.

Bastian Options, a cloth dealing with system integrator, bumped into many of those points when designing its ULTRA BLUE robotic truck-loading system. It wanted machine elements that would stand up to steady, high-cycle operation in dynamic, dust-prone environments.

The reply got here within the type of high-performance, lubrication-free movement plastics from igus.

Right here’s how the combination of polymer merchandise — together with plain bearings, linear guides, spherical ball joints, and slewing bearings — enabled Bastian Options to enhance ULTRA BLUE’s effectivity and reliability whereas decreasing prices.

Bastian builds ULTRA BLUE to enhance warehousing security

Bastian designed ULTRA BLUE to switch guide loading of bins and circumstances into truck trailers. By automating these high-volume loading operations, this cellular system addresses the bodily calls for and security dangers related to repetitive heavy lifting in warehouses and manufacturing services.

ULTRA BLUE can autonomously navigate between a number of dock doorways with out requiring rails, in-ground tools, or different extra infrastructure. Its elements embody a retractable mast, customized end-of-arm tooling (EOAT) with six levels of freedom and articulating conveyors.

The method works like this: Packing containers journey from an extendable conveyor connected to the again of the system, then up the mast. From there, the EOAT exactly locations the bins contained in the trailer from the bottom up utilizing lidar navigation.

ULTRA BLUE can deal with over 1,000 circumstances per hour in 24/7 operations and requires solely a single operator to handle a complete fleet by a centralized management interface.

Robotic operates in demanding circumstances

Not like different automated loading methods, ULTRA BLUE combines a number of capabilities right into a single, environment friendly answer. Designing it, nonetheless, required bearings and different machine elements that would deal with the robotic’s difficult operational setting. These circumstances included:

• Temperature swings: From humidity in the summertime to chilly temperatures within the winter, temperature fluctuations can affect the efficiency and lifespan of conventional steel bearings, which require specialised lubricants that may degrade below such circumstances.
• Mud and particles: The presence of particles and dirt as a result of corrugated bins can result in fast put on and tear in conventional elements, necessitating frequent pricey upkeep and bearing alternative.
• Numerous field circumstances: ULTRA BLUE should deal with quite a lot of packages, corresponding to skinny, bowing or broken bins which might be irregularly sealed and packaged, creating dynamic and probably high-impact hundreds on the inner mechanisms and bearings.

To deal with these challenges, Bastian Options wanted elements that would survive the robotic’s excessive cycle instances and dusty environments for lengthy intervals of time. Additionally they needed to assist heavy affect hundreds throughout operation.

igus gives lubrication-free answer

As a substitute of continuous to combat these upkeep battles, Bastian Options turned to igus for a strong and dependable answer, integrating a set of the corporate’s high-performance polymer elements into ULTRA BLUE. These included:

• Plain bearings had been utilized in a four-bar linkage mechanism pushed by a cam profile.
• Linear guides assist the linkage mechanism. Bigger customized guides had been additionally added to the system’s conveyor part.
• Spherical ball joints join two conveyor sections that pivot relative to one another.
• Plain slewing bearings had been included as a rear pivot of a conveyor part — an space that was inclined to clutter buildup.

The mixture of those elements addressed ULTRA BLUE’s operational challenges and efficiency necessities. For instance, a key design characteristic throughout all igus elements is their self-lubricating nature.

Not like steel bearings that demand common lubrication, igus bearings are created from high-performance plastics that include strong lubricants embedded inside the materials, eliminating the necessity for exterior lubrication and delivering a number of key benefits:

Diminished upkeep prices and downtime. The self-lubricating nature of igus elements reduces the labor, time and related prices of routine upkeep. For ULTRA BLUE, the flexibility to function throughout a number of shifts and cut back downtime is important for maximizing warehousing productiveness.

Contamination prevention. In environments with particles from corrugated bins, lubricants can entice and lure particles, resulting in untimely put on and contamination. Using igus bearings prevents these points, making certain cleaner operation and increasing part life. This characteristic has been particularly helpful for the slewing bearing utilized in a piece of ULTRA BLUE inclined to clutter buildup.

Suitability for harsh environments. The power to function reliably with out exterior lubricants makes igus elements appropriate for environments with temperature fluctuations, together with these during which ULTRA BLUE operates. In such circumstances, conventional greases are susceptible to thickening, thinning or degradation.

Parts to boost warehousing robotic sturdiness, cut back prices

Past fixing the upkeep issues, the igus elements enabled Bastian Options to scale back prices in a number of methods:

• For the four-bar linkage mechanism, switching to igus bearings not solely doubled the system’s life but in addition lower the part value by half.
• The spherical ball joint changed a costlier bearing and eradicated the necessity for a mud boot, additional simplifying design and reducing prices.
• The elements decreased buyer upkeep labor and spare half prices.

The igus elements even improved ULTRA BLUE’s design flexibility and efficiency. For instance, a key characteristic of the linear guides is clean, quiet operation, making the system’s operation extra environment friendly and fewer disruptive in busy warehousing environments.

Designed with exact tolerances, the spherical ball joints additionally promote dependable efficiency in dynamic functions, together with the ULTRA BLUE, whose two conveyor sections should pivot relative to one another.

Study extra about lubrication-free bearings

By implementing lubrication-free plain bearings, linear guides, spherical ball joints, and slewing bearings, Bastian Options efficiently met the operational and efficiency necessities for its ULTRA BLUE warehousing robotic.

To be taught extra about how igus elements can profit your robotic utility, go to: www.igus.com.