ANCA shows how AIMS can improve safety for tool manufacturers

ANCA provides a range of automation solutions, including the recent ANCA Integrated Manufacturing System (AIMS). AIMS, an ecosystem of individual modules, can be configured to build a tailored automated tool manufacturing system.

Modularity and flexibility mean that it should cater to both small and large enterprise type manufacturers. The system could be designed to be very simple, using a trolley for manual pallet and tool transfer with basic ERP connectivity. It could also be a complex, fully autonomous production solution which requires minimal human intervention. 

One of the components of a fully automated AIMS cell is AutoFetch – the AMR robot responsible for transferring pallets between the setting station, called AutoSet, to the tool grinder. It also automatically transfers single tools for spot check measurements outside of the grinder.

An AIMS cell is typically configured within a footprint of the existing factory with adjoining areas where standard, manual operations are taking place. 

There are generally two types of automatic vehicles used on the factory floor – AGV and AMR. AutoFetch is an AMR (Autonomous Mobile Robot) which is different to AGV (Automatic Guided Vehicle). The main difference is the way both units navigate their way around the factory. An AGV always follows a predetermined route which is defined by using various guiding aids like strips embedded in the floor, or reflectors fitted to the walls around the route.

The AMR travels from one location to another using its sensors and initially scanned map of the area. It doesn’t require any additional infrastructure to transfer material from A to B. It's designed so the user just scans and maps the relevant area during AutoFetch setup, mark the load and unload positions and then the robot, using algorithms, will find the optimal way from one point to the other. 

Autonomous material transfer with AutoFetch - safety implications  

One of the most common questions being asked is related to safety of the AutoFetch. This is understandable since AutoFetch operates alongside personnel in the factory. The AutoFetch AMR is designed to safely operate in a factory environment where people are present. The AMR moves from one station to another using an optimised route, and it constantly scans the immediate area for unexpected objects. 

When an object is detected, the AutoFetch will stop and navigate around it. Sensors - laser scanners, 3D cameras and proximity sensors - are used for this purpose. For extra security, an AMR prohibited area could be defined on the map to exclude autonomous traffic altogether. 

In addition, the AutoFetch could be programmed to reduce speed in certain areas and warn nearby staff with audio warnings such as beeper, horns, or pre-recorded spoken messages.   

72% of manufacturers report accidents related to using traditional means of material transport like pallet jacks, trolleys or forklifts. The use of AMRs contributes to increased safety in the factory and reduced accidents due to the elimination of human factors such as fatigue, lack of focus or awareness.