RFID in Robotic Cell Automation
Published on : Saturday 06-04-2024
RFID technology represents a paradigm shift in the optimisation of robotic cells within manufacturing environments.
Smart and Flexible manufacturing that can cater to the changing demands in the supply chain are the need of the day. Due to such changing trends the need for advanced automation products in field of sensing has increased tremendously. Technology and products too are in constant state of evolution.
In manufacturing industry efficiency, availability, speed and precision are paramount. Robotic cells have become indispensable in modern manufacturing processes as it not only streamlines production but also ensures consistent quality. However, to further optimise these processes, technologies like Radio-Frequency Identification (RFID) have emerged as game-changers. Applications related to Identification systems are the most sought out applications in the manufacturing Industry. It is not just limited itself to manufacturing industry but it has also found its need in retail and commercial world. Automatic Identification Systems allow you to track, monitor, report and manage products, documents, assets and people more effectively and efficiently as they move between locations.
Identification systems can be broadly categorised into two types, RFID based identifications system and Optical based Identification Systems (Barcode Systems). Though both the technologies are equally present in the market, but due to certain limitations like line of sight, no write capabilities and limitations to use in dusty environments, Optical identification has made way for RFID systems for a lot of industrial applications. RFID is one of the most emerging technologies in the field of identification.
Understanding RFID technology
Radio Frequency Identification (RFID) is one of the key members in the family of Identification and Data Capturing technologies. It is fast and reliable means of identifying object automatically. The two main components involved in a Radio Frequency Identification system are the Transponder (tags that are attached to the object) and the RFID reader. RFID technology utilises radio waves to transmit data wirelessly between a tag or label and a reader. These tags contain electronic information that can identify and track items, assets, or individuals with remarkable accuracy and efficiency.
RFID increases the speed and accuracy with which product/inventory can be tracked and managed thereby saving money for the business. RFID system consists of two components:
Tags – It is one of the integral components of RFID systems and it contains two parts. One is an integrated circuit for storing and processing data. The second is an antenna for receiving and transmitting the RF signals. The tags are available in different form factors and have different memory size based on the application requirements. These tags can further be classified into two types based on power source (with or without battery) or read write operations (read only and rewriteable).
Reader – An RFID reader is a device that is used to interrogate an RFID tag. The reader has an antenna that emits radio waves. The tag responds back by sending the information/data. RFID reader contains a module (transmitter and receiver), a controller unit and an antenna. The interface unit in the controller transmits the data read from the tag into the high-end system like PLC or PC.
RFID Bands – RFID systems operate in different frequency bands. They can all be grouped under the same RFID umbrella. Each frequency has its advantages and industries where it is often used. There are 4 major frequency bands available:
• Low frequency (125/250 KHz): The low frequency systems typically have a few inches of read range, are highly immune to metal in the environment and have good field penetration of water, grease and other nonmetallic substances. RFID systems operating at LF generally use passive tags, have low data-transfer rates from the tag to the reader.
• High frequency (13.56MHzHF): This frequency range allows a smaller coil size, which makes the tag less expensive. It is often used in logistical applications, asset tracking, and select factory floor applications. The low cost makes this tag perfect for high tag volume applications. These tags cannot be embedded in metal. In addition, they are often 3 to 4 times faster than the low frequency versions.
• Ultra high frequency (865-867MHz): A UHF system use passive tags and has a fast data-transfer rate between the tag and the reader. UHF RFID systems are used Tolling applications in public sectors. The UHF range is widely accepted in all types of application worldwide due to large reading/writing range and low-cost tags. It performs poorly in the presence of metals and liquids.
• Microwave frequency (2.45 GHz/5.8GHz): It can use both semi-active and passive tags, has the fastest data-transfer rate between the tag and the reader. These offer larger read write distances up to few 100mtrs and are widely used in applications related to Asset Monitoring.
Application of RFID – There are a wide range of applications where RFID technology is used.
Integration with robotic cells
The integration of RFID technology within robotic cells opens up a plethora of opportunities for enhanced automation and optimisation. By equipping robotic arms with RFID readers or embedding RFID tags within workpieces, components, manufacturers can achieve real-time tracking and traceability throughout the production process. In some of the cases it is not possible to integrate RFID tag onto the workpiece due to physical limitations. In these applications Direct Part Marking is done of the component by etching a Barcode or OCR code which then uses an optical identification technology.
Enhanced material handling
RFID technology revolutionises material handling within robotic cells by providing accurate inventory management and asset tracking. With RFID-enabled tools, pallets, or containers, robotic arms can identify, locate, and manipulate materials with precision, minimising errors and reducing downtime.
Streamlined production processes
The real-time data capture capabilities of RFID streamline production processes within robotic cells. By automatically identifying workpieces and retrieving relevant production instructions or parameters, robots can adapt dynamically to changing manufacturing requirements, optimising efficiency and flexibility.
Quality control and traceability
Maintaining stringent quality control standards is essential in manufacturing. RFID technology facilitates seamless quality control within robotic cells by enabling the tracking of individual components which are used in the throughout the assembly process. By associating quality data with RFID tags, manufacturers can ensure compliance with regulatory standards and swiftly address any deviations or defects.
Workforce safety and security
Incorporating RFID technology enhances workforce safety and security within robotic cells. By tagging personnel with RFID badges or wearables, manufacturers can monitor employee presence and location in real-time, preventing unauthorised access to hazardous areas and ensuring compliance with safety protocols. The entry inside the Robotic cell is protected by using modern interlocking devices or guard locking switches. They are based on non-contact transponder technology (RFID) and consist of a coded actuator, read head and evaluation electronics.
Predictive maintenance
One of the key advantages of RFID technology in robotic cells is its contribution to predictive maintenance strategies. By monitoring the usage patterns and performance metrics of robotic components through RFID-enabled sensors, manufacturers can anticipate maintenance needs, prevent unexpected breakdowns, and optimise equipment lifespan.
Challenges and considerations
While the integration of RFID technology offers numerous benefits, it also presents challenges that need to be addressed. These include initial investment costs, interoperability with existing systems, data security concerns, and potential environmental factors affecting RFID performance. However, with careful planning and implementation, these challenges can be mitigated, paving the way for transformative advancements in robotic cell automation.
Future directions
Looking ahead, the role of RFID technology in robotic cells is poised for further innovation and expansion. Advancements in RFID tag miniaturisation, enhanced data analytics capabilities, and interoperability with emerging technologies such as Internet of Things (IoT) and Artificial Intelligence (AI) will unlock new possibilities for optimisation, efficiency, and customisation in manufacturing processes.
Conclusion
In conclusion, RFID technology represents a paradigm shift in the optimisation of robotic cells within manufacturing environments. By enabling real-time tracking, traceability, and automation, RFID gives power to the manufacturers to enhance efficiency, quality, and safety while laying the groundwork for future innovations. Implementation of RFID technology within robotic cells is not just a step forward – it’s a leap towards the future of manufacturing. This technology can be a real game changer; the only limit is our imagination!
Article courtesy: Pepperl+Fuchs Factory Automation
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