The project in five facts.
Challenge, approach and results.
The diploma thesis addresses the automation of a mechanical production process by introducing an industrial robot as a replacement for the existing system with linear drives. The purpose of the work was to demonstrate how modern automation solutions can improve the efficiency, reliability and safety of the production process, whilst reducing operational errors and enabling adaptability for different product types. The process examined was a mechanically implemented system for turning metal workpieces in a machine, which frequently caused stoppages and inaccurate movements due to wear of linear drives and required intensive maintenance. Particular emphasis is placed on the use of the FMEA method, which analysed possible failures in the phases of gripping and depositing the workpiece, robot movement and communication between the robot and the machine, and proposed specific preventive measures.
Problem
The diploma thesis addresses the automation of a mechanical production process by introducing an industrial robot as a replacement for the existing system with linear drives. The purpose of the work was to demonstrate how modern automation solutions can improve the efficiency, reliability and safety of the production process, whilst reducing operational errors and enabling adaptability for different product types. The introductory section of the diploma thesis presents the problem definition, purpose, objectives and methodological approach.
Solution and Method
The process examined was a mechanically implemented system for turning metal workpieces in a machine, which frequently caused stoppages and inaccurate movements due to wear of linear drives and required intensive maintenance. These shortcomings negatively affected throughput, reliability and safety of the working environment. The core of the work comprises a technical description of the existing system, the phases of selection and integration of the KUKA KR 6 R700-2 robot, mechanical and safety adaptations, and upgrading of software functions.
In the safety segment, emphasis was placed on eliminating dangerous manual intervention in the machine, as the new solution included a safety cell and mutual communication between the machine and the robot.
Results
Particular emphasis is placed on the use of the FMEA method, which analysed possible failures in the phases of gripping and depositing the workpiece, robot movement and communication between the robot and the machine, and proposed specific preventive measures. Based on the analysis, system reliability was improved, the possibility of critical failures was reduced and control over operation was optimised. The results of the diploma thesis confirm that automation enables shorter machine downtime due to fewer stoppages, higher repeatability of movements and easier adaptation to production changes.
The hypotheses, including more than 15 per cent improvement in efficiency, reduction of errors and return on investment in less than two years, were confirmed with analytical data. The conclusion emphasises the importance of linking theoretical knowledge with real technical challenges, whereby the case examined proved to be good practice that can serve as a model for further automation in industry. The work offers insight into modern digitalisation trends and makes an important contribution to understanding the practical benefits of automation in the context of sustainable and competitive production.
Module, programme and stories.
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