KUKA Robotics UK Limited

KUKA's Orange Week Discount Returns, with Spares Savings for Ecommerce Customers

KUKA Robotics UK Limited — 21/11/2023

Orange Week returns on the 27th of November 2023, for two weeks until the 8th of December.

KUKA's annual eCommerce discount was borne of Black Friday, with a twist in the name that aligns with the firm's corporate branding.

So, what is Orange Week?

In essence, it is an opportunity for customers to take advantage of discounted spare parts when ordered online via the my.kuka/marketplace commerce platform; an online shop for all KUKA products. The discount can be applied to spare parts as well as repair and replacement parts.

Why purchase spare parts?

Ordering spare parts for robots ensures the uninterrupted functionality of robotic systems. Having a stock of spare parts readily available minimises downtime in case of unexpected part depletion or wear and tear, thereby optimising operational efficiency.

This proactive approach also contributes to cost savings by reducing the impact of potential delays in production or services. Additionally, it facilitates quick and timely maintenance, extending the overall lifespan of the robotic equipment. Having an inventory of spare parts enhances production reliability.

What is my.kuka?

The KUKA Marketplace offers everything our customers need: more than 25,000 products across robots, software products, spare parts, and services. Registration is free.

Find out more about Orange Week here

Already a KUKA customer and wish to register for my.kuka - Register here

See the video 'Getting Started with my.kuka'

KUKA Robotics: Meeting the Skills Challenge

KUKA Robotics UK Limited — 10/08/2021

KUKA Robotics: Case Study - Advanced manufacturing training centre of excellence, Dundalk, Ireland

MEETING THE SKILLS CHALLENGE

Two years of hard campaigning for cutting edge manufacturing training has paid off as the newly established Advanced Manufacturing Training Centre of Excellence located in Dundalk, Ireland, prepares to welcome its first students on site in September 2021. Michael McGrath Director explains what the centre will be doing and the essential role of its partnership with KUKA Robotics.

The challenge of training technical skills is not new, in Ireland or any other advanced industrial economy. The Louth Meath Education and Training Board (LMETB) Advanced Manufacturing Training Centre of Excellence (AMTCE) in Dundalk has been established to do exactly what its name says, across a range of sectors and activities. It has taken a 10-year lease on a 55,000 sq ft (5110 sq m) building owned by the Irish Development Agency in the Xerox Technology Park that was vacated by Teva Pharmaceutical Industries, which has relocated its activities to a laboratory in Croatia.

“When we committed to this building shortly before Christmas 2020, it was the culmination of a two-year campaign of lobbying, raising finance and putting in place the necessary support from the government and from industry, headed by Martin O’Brien, LMETB Chief Executive,” says Michael McGrath, Director, who came on board specifically to run the AMTCE project. Irish Government grant funding of EU4.5 million is part of the EU28 million Brexit stimulus package and EU 17 million Border Enterprise Development. There is also support from Northern Ireland, from the Portview Enterprise Centre in East Belfast.

A first in Ireland

The AMTCE is the first such establishment in the Republic of Ireland. Previously, employees and younger learners seeking to develop advanced skills in areas such as robotics, augmented reality (AR), automated visual inspection systems, 3D printing, and computer aided manufacturing had to travel to other countries to do so; typically, to facilities in Germany or the United Kingdom.

The AMTCE was initially intended to take in 1,600 trainees in 2021, across a range of courses. The site had been intended to open in early 2021; this was delayed by measures taken in response to the Covid-19 emergency. Some activities have already started, with self-directed online learning and trainer led virtual classrooms, while the premises are being modified and refurbished to meet the needs of the AMTCE, including building workshops and laboratory facilities. Initial onsite courses will be available from September 2021.

Traditional and contemporary skills

“The interior space is being reconfigured to allow us to deliver a fairly wide range of courses that are relevant in the context of industry on the Island of Ireland ,” McGrath says. “These courses will be related to robotics, cobotics and robotic processes.” For example, the AMTCE will offer a continuum of courses, starting with virtual reality training to help students acquire the basic hand skills and ‘muscle memory’ needed for welding, which will enable them to work safely when they move on to traditional MiG, TiG and rod welding, and progressing over a period to robotic welding skills.

“We will also have traditional workshop facilities for the teaching of milling, bending, forming, cutting, heat treatment processes and so on, with an emphasis on engineering and a focus on accuracy and precision,” he explains. “We have CAD labs on site as well, which means that students will be able to spend time designing pieces before putting it onto the CNC machines. We will also have a number of multi-material routers and precision metrology equipment in the same area.”

The word “student” tends to prompt an image of a young person, a recent school graduate, but AMTCE’s offer goes beyond first-level basic training. It is a lifelong learning facility, offering upskilling and reskilling for adults, as required and as appropriate for the engineering and manufacturing community on the Island of Ireland. There is a strong need for skilled welders and this is a priority for the Centre.

A range of courses and teaching methods

“There is a severe shortage of skilled welders in Ireland,” McGrath explains. The need means that the AMTCE has deliberately produced a strong welding training facility. In addition to its seven robotic welding cells, it has 18 ‘educate’ cells; four cobot cells; as well as two machining robots. KUKA has supplied all 31 complete robot cells.

“Initially, we were talking to several vendors with a view to running a 10-week robotic welding course but, given the high demand for welders, we found that there might be some difficulty populating it,” he continues. “There is a 16-week national certified welding course taking people up from novice to a reasonable level of skill and the suggested 10-week course would have essentially cannibalised that.”

After discussions with engineering companies, employers and vendors, the AMTCE determined on a range of courses, running from five days to 10-weeks, building to a comprehensive 26 weeks of linked, coherent training.

“We’re looking to run short, specific courses on traditional welding and robotic welding as well as linking with KUKA’s five-day courses for experienced people seeking to upskill to robotic welding, for example,” says McGrath. The VR/AR training and Future Rooms, AI (artificial intelligence) Chatbot personalised distance learning, eLearning, the MyKademy web-based virtual classroom, community hub and CRM learning management tool all adds up to what the Centre is calling the AMTCE 360^O Learning Solution.

KUKA Cell4 concepts

KUKA robots feature heavily in the on-site learning and teaching resources, with a total of 31 KUKA robot cells. The “Cell4” concept cells being installed in AMTCE are a range of compact, portable cells on a base frame that can be adapted or preconfigured to a broad spectrum of applications. The KUKA cell4_Arc units are preconfigured MiG/MAG cells, delivered ready for operation and typical of the kind of cells that students will be using in contemporary factories.

As in commercial settings, the Cell4_Arc cells are configured with the range of standard packages for steel and aluminium welding, including torch cleaning systems and Fronius TPS 320i to 500i FE, and TPS 400i AL and 500i AL welding systems and for various production volumes. The standard cell dimensions of 8120mm x 3010mm x 3020mm height can accommodate single or dual KR Cybertech robots within compact dimensions; again, as used in the ‘real world’ of industry, where space is often at a premium.

Partners in education, training and development

Why opt for KUKA robots?

“The AMTCE considered a number of vendors and there were a few considerations that led to us choosing KUKA,” McGrath says. The selection involved an open EU Tender process; KUKA was selected ahead of several competitors, with a bid that was both technically compliant and offered best commercial value. Its main Republic of Ireland facility is located just a few miles from AMTCE. “That proximity makes it very easy to engage with them. They can provide a strong level of support, which is key in developing a partnership model, and we wanted something more than just a vendor-customer relationship. They are able to adapt to our needs, too.”

“KUKA has a training facility in Dundalk, as well,” McGrath continues. “which offer training on their premises, they have people who are experienced at delivery and they are clearly committed to the value of education.”

The Louth Meath Education Training Board Advanced Manufacturing Training Centre of Excellence will also create and facilitate collaboration with businesses in the area, including project and product development, in a similar way to the High Value Manufacturing Catapult network in the UK. It will be a highly capable, modern and technologically advanced facility when it opens, and the partnership with KUKA will help it remain contemporary, relevant and a vital resource for the manufacturing sector in Ireland in the years to come.

Cobots and Augmented Reality for Electronics Assembly

KUKA Robotics UK Limited — 24/11/2023

Industrial augmented reality (AR) work instruction platform from LightGuide seamlessly integrates with a wide variety of digital manufacturing technologies, including cobots.

Here, LightGuide is integrated with KUKA’s LBR iisy cobot to combine the benefits of industrial automation and digital work instructions to streamline the process of assembling an electrical component.

Assistive technologies enable the management of diverse manufacturing tasks, utilising the best elements of automation and human performance, autonomously.

The cobot completes the precise, repeatable tasks that automation does best; applying a consistent glue path across the lid of the enclosure. In tandem, the worker follows the augmented reality (AR) work instructions to complete a wide range of complex manual aspects of the component assembly.

Follow this link to watch a video of the application in action

See the LBR iisy promotional video below

KUKA posts record robot sales despite challenging year

KUKA Robotics UK Limited — 26/01/2021

KUKA Robotics in the UK and Ireland has posted the strongest annual sales figures in the company’s history, despite the challenges of the Covid-19 crisis and the consequential recession. The group attributes the success to its proven sales strategies and to four main strategic factors that combined to make 2020 a record year.

With the rise of e-mobility, driven by customer demand for green modes of transportation, the automotive sector has undergone big changes in vehicle design and propulsion. KUKA has been at the forefront of automation for e-mobility production and a big cause for celebration was a large order from commercial electric vehicle manufacturer Arrival, a new company with a unique production model.

Every Arrival vehicle is produced in a relatively small and low cost “microfactory”, each of which can produce 10,000 vans or 1,000 buses per year. The company has already announced an order of 10,000 electric vans from logistics company UPS, with the option for a further 10,000; production in the UK is now supported by Arrival’s first US microfactory, in York County, South Carolina.

KUKA UK is supplying the robots for Arrival’s rising demand, across the world. CNBC reported in November 2020 that Arrival was aiming to build three to four of these factories a year, each serving a city and its community, linked in a global framework. The potential for future use of robotics and automation from KUKA is very promising.

“The UK automotive sector faces big challenges, but electrification is coming fast and, with winning the Arrival contract, I am confident that KUKA is very well placed to capitalise on this growth market,” says Paul Williams.

KUKA UK appointed a specialist automotive account manager, Paul Williams, in late 2019. With a strong track record in automotive robot applications, Paul has already made big in-roads into the sector. “KUKA is embedded in the big car plants in Germany but we are not as well established in automotive in the UK, for legacy reasons,” Bernard Bagley, Head of Robot Sales, KUKA UK. “Paul and the Arrival contract are helping to change that.”

KUKA has restructured its sales teams under General Industry, in order to cover sectors and regions simultaneously and efficiently. Now, every sales manager targets an industry sector as well as a geographic footprint. Along with KUKA’s System Partner model of partnering with specialist integrators, the approach is much more customer-facing. KUKA brings projects to its System Partners and vice-versa; KUKA sales engineers and System Partners always “walk the floor” to help advise on optimum automation strategies and act as a trusted advisor.

“This change has generated a lot more interaction with end-customers, which has always been our goal,” says Bernard. “Our System Partners provide this customer focus and our restructured sales team is now doing the same.”

Thirdly, KUKA has crystallised its strategy for Education and Research and Development. KUKA has always believed in the fundamental need for appropriately skilled operators, technicians and engineers, in order to extract the best out of automated machines, assembly lines and research projects. KUKA UK and Ireland have invested heavily in supporting the education and research sectors and have developed dedicated educational robot cells and training material, alongside bespoke research cells focused on emerging technologies.

KUKA Ireland recently won a significant tender to supply the Louth & Meath Education and Training Board (LMETB) with a range of educational and collaborative robots for its new state-of-the-art Advanced Manufacturing Technology and Training Centre of Excellence (AMTCE) in Dundalk, Co. Louth. The training facility at the Centre, which is set to be the largest vocational training facility of its kind in Europe, includes tailored educational industrial 6-axis robots with vision systems, robotic welding cells, robotic milling/machining cells and collaborative robot (cobot) cells.

Brian Cooney, Managing Director of KUKA Ireland, says “Manufacturing is experiencing a serious skills gap and shortage of resources in advanced manufacturing technologies at vocational level, which is not being addressed by the third level colleges and universities. The investment by the LMETB in this visionary AMTCE training centre is not only addressing this skills gap in Ireland but is also setting the standard by which other European centres may be measured.”

The AMTCE provides tailored training courses to upskill and reskill operators and technicians and forms a critical component of the Irish Government’s Industry 4.0 Strategy 2020-2025 program and Covid-19 recovery plan.

KUKA Robotics is the only robot manufacturer with a dedicated presence in Ireland with local sales, customer service, application engineering and training. “This recent success is testament to our focus on providing the best possible products and service to our customers. This is never more important than starting with the operators and technicians who will be responsible for the continued success of our manufacturing sectors,” says Brian Cooney.

KUKA UK and Ireland enters 2021 with a very strong team, with experts in sectors, applications, and regions across the board, together with a network of independent Platinum, Gold and Silver level System Partners, who deliver first class solutions and consultancy centred on their core competencies.

Looking to 2021, KUKA believes the robotics and automation sectors are set for significant growth in response to increased demand to offset the heavy reliance on ever scarcer resources, to reshoring, and to escalate efficiencies and competitiveness in manufacturing. New social distancing requirements in factories and workplaces increase the need for automation to create safe working environments within a limited floorspace.

The life-science sector, including medical device, pharmaceutical and biotech, is a notable growth market. Laboratories are presenting new applications for robots and cobots, especially in labs and clean rooms, that require precise, repetitive processes where a robot can provide the consistency, reliability and traceability that such a highly validated process demands.

Brian Cooney says that, while 2020 has been a difficult year for many manufacturing sectors suffering under the double impact of Covid-19 and the uncertainty around Brexit, it is widely expected that there will be a strong bounce back in the UK and Irish economies in 2021 and beyond. With the benefits of Industry 4.0 and digitisation, together with incredible advances in manufacturing technologies, KUKA expects to take its record 2020 success into 2021 and deliver continued growth, despite the economic challenges.

3D printing is revolutionising manufacturing

KUKA Robotics UK Limited — 20/09/2023

3D printing, or additive manufacturing, is revolutionising modern manufacturing. Its impact extends across many industries, as it changes the production landscape and advanced product development.

Here are 10 Reasons Additive Manufacturing is Driving Manufacturing Forwards

Additive manufacturing, also referred to as 3D printing, is revolutionising the manufacturing industry by providing a cost-efficient alternatives to traditional manufacturing processes. Here are some key ways in which additive manufacturing can help businesses to achieve cost-efficiencies and optimise product output in a market that requires product ‘on-demand’.

Reduced Raw Material Waste:

Traditional manufacturing methods often involve subtracting material from larger workpieces (milling and machining) which not only results in significant material waste, but also increased time to manufacture and additional energy usage. In contrast, additive manufacturing enables components to be built layer by layer, using only the material needed for the final product. By minimising waste, cost savings can be applied to other areas, such as R&D.

Complex Geometries without the High Cost:

Additive manufacturing allows for the creation of complex and intricate designs that would be challenging or almost impossible to achieve using traditional manufacturing methods. With traditional manufacturing, complex shapes often require both expensive tooling and multiple steps that ultimately drive up production costs. In contrast, additive manufacturing can create these complex geometries in a single step, that is often more cost efficient and quick!

Faster Prototyping and Product Iteration:

Additive manufacturing enables rapid prototyping. Often designers and engineers work alongside one another to quickly create and test prototypes – In competitive market sectors, such as automotive, reacting to changing market trends and consumer demand is imperative. This speeds up the product development cycle and reduces the time and cost associated with design testing and product revisions thereafter.

Customisation and Batch Size:

Additive manufacturing is well-suited for producing customised and low-volume, high-value parts. Traditional manufacturing processes can require expensive tooling and setup costs, which make them less cost-efficient for small production runs. Additive manufacturing doesn't have these constraints, supporting the ‘batch-of-one’ principle, making it economically viable for one-off or small-batch production runs. Additive manufacturing therefore supports lean manufacturing and ‘just-in-time’ methodologies.

Elimination of Costly Assembly Steps:

Additive manufacturing can be used to produce parts with intricate internal structures, reducing the need for assembly – typically such components would have been produced in multiple parts, and joined together afterwards. In traditional manufacturing, complex assemblies would be time-consuming and costly – There was also the question of product integrity: how reliable would a part be formed of multiple components, compared to that produced as one solid piece? Additive can produce a single, integrated component, streamlining production and reducing costs.

Reduced Inventory Costs:

Traditional manufacturing often requires maintaining large inventories of parts to meet production demands. Not only does this involve the upfront costs associated with sourcing product, but there are also the costs associated with storage. Additive manufacturing allows for on-demand production, reducing the need for inventory storage and associated carrying costs. Supply chain challenges can also be mitigated.

Localisation and Supply Chain Optimisation:

Additive manufacturing can be deployed closer to the point of need, reducing both transportation costs and lead times. This is particularly beneficial in industries where rapid response and customisation are essential, such as aerospace, rail, marine, medical, even fashion! The benefits are further substantiated by the delivery of mobile, standardised cells, that can operate on a dock, in a shop or within a medical facility.

Material Efficiency:

Some additive manufacturing processes, like powder bed fusion, can recycle unused or excess material for future builds, further reducing material costs. Some polymers used in 3D printing can be recycled and repurposed within prototyping exercises. There now also exists the potential to utilise multiple materials in the same manufacturing cycle.

Reduced Tooling Costs:

Traditional manufacturing often requires expensive moulds, dies, and tooling for individual parts. Additive manufacturing eliminates or reduces the need for such tooling, leading to further cost savings. Tooling can also break during the manufacturing process, in milling and grinding for example. By eliminating the need for tooling, time constraints associate with sourcing new tool parts is mitigated.

Sustainability:

By minimising material waste and offering energy-efficient processes, additive manufacturing can contribute to sustainability efforts, which not only lead to cost savings through environmental incentives - consider energy savings and materials usage, but reduced waste disposal costs after the manufacturing process has completed. Consumers are also becoming more sustainability savvy and will actively seek a supplier or manufacturer whom are both environmentally responsible and aware of their impacts upon their surroundings.

The adoption of 3D printing is driven by advancements in materials, technology, and increased awareness of its capabilities. As more industries realise the benefits of 3D printing, we can expect its uptake in new sectors and innovative applications. The construction industry is already using 3D printed concrete structures, to save costs and enable the development of sustainable building materials. The medical sector used 3D printing for the manufacture of prosthetics and bone grafts, and orthodontic devices in dentistry. Custom parts for turbines, solar panels, and other energy-related equipment in the energy sector are being 3D printed and even the technology is even being utilised in the arts.

KUKA’s standard mobile 3D printing cell, KUKA cell AM, can play a crucial role in enabling manufacturers: supporting agility and responsiveness to changing demands. By leveraging the flexibility and adaptability of standardised 3D printing technology, manufacturers can optimise their production processes, reduce lead times, and efficiently meet evolving customer needs.

Below, the KUKA cell AM, additive manufacturing cell.

An exciting future as Birmingham University & KUKA Systems UK Ltd. collaborate

KUKA Robotics UK Limited — 20/09/2023

Universities are hubs of specialised knowledge and research expertise. Collaborations between academics and manufacturers are important in research and development (R&D) initiatives, with partnerships often at the forefront of innovation - exploring the utilisation of cutting-edge technologies and developing ideas for industry.

Collaborating with universities allows manufacturers to tap into the intellectual resources of professors, researchers, and students who have deep knowledge in a wide range of disciplines. This expertise can enhance both the quality and depth of research and development efforts.

KUKA Robotics UK Ltd. has a strategic focus upon the development of automated technology into industry, with established research partnerships in academia and across the CATAPULT network, led by Alan Oakley. These innovative environments enable collaborative insights into new concepts, methodologies, and research findings that may lead to breakthroughs in product development and manufacturing processes.

Mike Russell, KUKA Systems UK Ltd. - Moataz Attallah, Birmingham University - Alan Oakley, KUKA Robotics UK Ltd.

One such partnership, with the University of Birmingham, has been established for in excess of 12 years, with state-of-the-art robotic technology being utilised to support their research infrastructure.

Looking to the future, and to compliment that association, a recent visit to the University of Birmingham, by KUKA Systems UK Ltd. took place, to identify ways in which the two enterprises can work together in developing advanced metallic manufacturing processes. KUKA’s advanced welding solutions, based out of Halesowen, has developed advanced manufacturing competencies that align with current initiatives being undertaken at Birmingham – sustainable, lightweight, advanced metallics that address many of the challenges being encountered in modern manufacturing today.

Mike Russell MEng, PhD, CEng, MWeldI, MBA, FCMI, CMgr - CTO, KUKA Systems UK Ltd. joined KUKA with a view to elevating our brand presence in the international advanced welding arena. Already having established relations with the University of Birmingham, through Professor Moataz Atallah Director, The Advanced Materials Processing Lab. (AMPLAB), Director of Research & Knowledge Transfer, School of Metallurgy & Materials - the two share a common interest in solid-phase processes and both have a profound knowledge and extensive experience in metallic compositions and welding, studying for their respective PhDs together. With a mutual, long term vision on the research and development of metallic joining and manufacturing, a road map, designed to bring a wide range of perspectives and ideas to collaborative R&D projects, fostering creativity and innovation, is to be established between KUKA Systems UK Ltd. and Birmingham University.

Advanced welding finds application in a wide range of industries where the joining of high performance materials is crucial, and the demand for high-quality, energy efficient welding solutions is paramount. Rotary friction welding, linear friction welding, and friction stir welding are much sought after, with demand arising from the need for stronger, lighter, and more durable materials in sectors such as automotive, aerospace, energy, construction, and manufacturing. These industries also require welding solutions that can support the transition to Net Zero manufacturing, via the efficient fabrication of high-performance components.

Though research and development is not just limited to metallics. Further, already well established, projects in robotic EV-automotive battery assembly/disassembly and automated nuclear decommissioning are currently being undertaken at Birmingham University, where the utilisation of KUKA’s industrial robots are paving the way to optimised development cycles in niche and evolving industry sectors - These collaborations shall facilitate the transfer of knowledge between academic research and industrial development, and the findings applied in practical manufacturing processes.

In summary, a collaboration between Birmingham University and KUKA in R&D can lead to a synergistic relationship that shall drive innovation, reduce costs, mitigate risks, and ultimately result in the development of new products and technologies with a competitive edge in the global marketplace, that is crucial for advancing technology, staying competitive, and addressing complex manufacturing challenges.

Robotics isn’t complicated when it’s this iisy

KUKA Robotics UK Limited — 27/07/2023

Technology that is easier to manage is often embraced by more people due to the inherent appeal of convenience and efficiency - we naturally gravitate towards simplicity. KUKA is making robotics accessible to everyone, even those with no previous robotics experience.

Welcome to the LBR iisy

In a fast-paced world, where time is of the essence, straightforward and manageable robotics become attractive choices. The simple set-up of the iisy instils a sense of confidence: users feel more in control and empowered when interacting with the uncomplicated, collaborative robotic tool. It's user-friendly instructions and straightforward assembly processes promote ease-of-use, ensuring that more people can reap the benefits with minimal barriers.

Unboxing and commissioning a robot should be quick and iisy

Manufacturers understand the importance of straightforward setup to minimize any potential barriers in the adoption of new robotic technologies. By designing packaging that allows easy access to components and providing clear step-by-step instructions, KUKA has made it eminently easy to rapidly unbox the LBR iisy and guide users through a hassle-free set-up process - even those with minimal technical expertise are able to get the collaborative robot up and running efficiently. The emphasis on quick and easy unboxing and commissioning not only saves valuable time for users but also enhances the overall user experience, making the utilization of the robot accessible and enjoyable, whatever the industry and eventual application.

Digital tools are revolutionizing the manufacturing industry

Transformative change across its landscape is well established. By integrating advanced technologies, manufacturers are optimizing their production processes, enhancing efficiency, and unlocking new levels of productivity. Among these game-changing innovations, collaborative robots have emerged as a standout example.

The LBR iisy is designed to work alongside human operators, leveraging their capabilities to augment and complement human tasks rather than replacing them. Equipped with sophisticated sensors and programming, the iisy collaborates safely and seamlessly with humans*, fostering a harmonious human-robot interaction.

By incorporating the LBR iisy into their operations, manufacturers can achieving greater flexibility, faster turnaround times, and improved precision in tasks that require repetitive and laborious efforts. The integration of collaborative robots into the manufacturing workflow exemplifies how digital tools are driving the industry's transformation, elevating it to new heights of competitiveness, and propelling it into an era of unprecedented progress.

It's as iisy as 1, 2, 3…

Don’t take our word for it – See how our UK & Ireland Marketing team got on, unboxing and setting up the LBR iisy, with no previous robotics experience.

Everything is hard before it is iisy

Watch the video here

*Application dependant

Mike Russell joins KUKA Systems UK with a focus on developing welding portfolios and overseas channels.

KUKA Robotics UK Limited — 27/07/2023

With an impressive background of business development in advanced welding and a passion for cultivating strategic partnerships, Mike brings a wealth of experience and expertise to our organisation, supplemented by formidable academic credentials that include a Master’s Degree in Materials Engineering and Ph.D. on the ‘Development and Modelling of Friction Stir Welding’.

Mike has a proven track record of driving growth and establishing successful collaborations in diverse markets that will elevate KUKA’s presence in the international advanced welding arena. With a deep understanding of market dynamics, coupled with his innovative approach, Mike will enable KUKA to identify and capitalise on new opportunities overseas.

Jeff Nowill, KUKA Systems UK CEO, said of Mike’s appointment: We are thrilled to have Mike on board, and we are confident that his contributions will propel our company towards greater achievements in the advanced welding solutions marketplace. His keen eye for identifying emerging trends and consumer demands will guide our company's portfolio development, ensuring that we remain at the forefront of the industry.

Advanced welding is a rapidly growing market due to several factors that have contributed to its increased demand and adoption. One of the key drivers is the advancement in technology, which has led to the development of innovative welding techniques and equipment – Mike’s proven experience and deep understanding of these techniques, their features and benefits, will enable us to navigate new, international markets”.

With project delivery successes in collaboration with some of the world’s biggest brands, such as: Airbus, Apple, Boeing, Bombardier, Lockheed Martin, Sapa and Tesla, plus many others, Mike’s experience of strategic portfolio development is impressive.

On joining KUKA, and of his immediate future ambitions within his new role, Mike said: “I would like to develop and deliver an R&D roadmap and research programme, to support the generation of new capabilities and new market opportunities for the business. My ambition is for KUKA’s solid-phase team to be unequivocally recognised as being the best in the world at what we do”.

Mike continues: “Having worked with KUKA in the past, I have always been impressed by the quality of the equipment produced and the business’s strong focus on customer service. This role is a great progression for me from the world of solid-phase research, and an opportunity to experience, first hand, the supply of specialist equipment and solutions”.

KUKA Systems UK warmly welcomes Mike to our family, and we look forward to the contributions he will make in driving our company forward.

If you would like to understand more about the friction welding process, you can contact Mike via email, at: mike.russell@kuka.com

Automation is Imperative : A Call to Action for UK Manufacturers

KUKA Robotics UK Limited — 31/01/2024

In today's dynamic global manufacturing landscape, the integration of automation and robotics has become a cornerstone for maintaining competitiveness.

Now, more than ever, as technology advances at an unprecedented pace, the decision to automate is not just strategic but one of commercial survival. The absence of automation, coupled with the attitudes of UK manufacturers towards robotics and automation, poses a significant challenge to the UK's ability to compete with low-cost alternatives, especially from the Middle East, where the widespread adoption of robots has been widely publicised. Understanding why UK manufacturers are hesitant to adopt automation is crucial if they are to succeed in today's market.

The Rise of Automation in Manufacturing
Automation in manufacturing involves the use of technology to perform tasks with minimal human intervention. Robotics, artificial intelligence, and advanced machinery have become integral components in modern factories, contributing to increased efficiency, precision, and productivity. In the context of global manufacturing, countries that embrace automation are better positioned to meet the demands of rapidly changing markets.

The Middle East's Leap into Automation
One notable example of a region making significant strides in automation is the Middle East and Asia. Many Eastern countries have recognised the need to diversify and have turned to automation as a means of achieving economic transformation - As a whole, the continent of Asia led the way in robotics installations in 2022. The new World Robotics report recorded 553,052 industrial robot installations in factories around the world in 2022. By region, 73% of all newly deployed robots were installed in Asia. The continued adoption of robotics and automation is enabling Middle Eastern manufacturers to produce goods more efficiently and at a lower cost. By comparison, the UK is falling woefully behind, not even featuring in the top 15 largest markets and unable to compete.

The Competitive Edge of Tech-Savvy Manufacturers
The embrace of automation by tech savvy manufacturers is giving them a competitive edge over counterparts that lag in automation adoption. With streamlined production processes, reduced labour costs, and improved product quality, these manufacturers are better equipped to offer products at more competitive prices on the global market. As a result, they are gaining ground and challenging the dominance of traditional manufacturing.

Challenges Faced by UK Manufacturers
In contrast, some UK manufacturers are hesitant to fully embrace automation due to various factors, including concerns about job displacement, initial investment costs, and a lack of awareness about the transformative benefits of automation. However, failure to adapt to the changing landscape may result in diminished competitiveness and market share, ultimately failure. But there are multiple benefits to adopting robotics, not just for the commercial gains, but also to future proof operations to sustain operational longevity. Consider the appeal to the next generation, who whilst may not be overly enamoured at the prospect of becoming a welder, but may be drawn to the opportunity of becoming a robot programmer. Adopting automation also sends a very definitive message to your customers – you are looking to the future, you are innovative, you are investing.

Job Displacement Myth
One common misconception surrounding automation is the fear of job displacement. While it is true that certain routine tasks may become automated, the overall impact of automation on employment is nuanced. Automation often leads to the creation of new, higher-skilled jobs in areas such as robotics maintenance, programming, and system management. Moreover, by enhancing efficiency and competitiveness, automation helps secure the long-term viability of the manufacturing sector, safeguarding and creating jobs along the supply chain in the process: administrative staff, drivers, warehouse/inventory staff…

Investment in the Future
While the initial costs of implementing automation systems might be significant, it is crucial to view them as strategic investments in the future. The long-term benefits, including increased production capacity, improved product quality, and enhanced competitiveness, far outweigh the initial expenses. Governments and industry stakeholders should collaborate to create policies that incentivise and support the adoption of automation technologies by providing financial assistance and educational programs, such as those widely delivered across Ireland.

The Path Forward for UK Manufacturers
To remain competitive in the global manufacturing arena, UK manufacturers have to recognise the urgency of embracing automation, now. By investing in advanced technologies, optimising production processes, and upskilling the workforce, they can position themselves as able players in the international market, across multiple industries, from Food & Bev to welding,

Incredibly the Make UK Executive Summary revealed that 71% of firms agree that digital tech will drive productivity. This includes digital tools such as robotics, cloud, data analytics, and AI. Despite the awareness of the benefits of digital tech, investment in automation is still lacking.

To conclude
The lessons from the East serve as a stark reminder that failing to adapt to the era of automation may lead to a gradual erosion of competitiveness. Automation is not merely a technological luxury; it is a strategic necessity for manufacturers aiming to thrive in the current global landscape. The adoption of automation by Middle Eastern countries is pushing them further and further ahead in the race for global competitiveness. UK manufacturers must act to overcome their reservations and invest in technology that will define the future of manufacturing. Embracing automation is not just about staying ahead—it is about securing a place at the global manufacturing table.

The Rise of Welding Robots in the World of Precision Manufacturing

KUKA Robotics UK Limited — 14/11/2023

In the dynamic landscape of precision manufacturing, the rise of welding robots has revolutionised the industry, ushering in a new era of efficiency, precision, and productivity.

These advanced robotic systems have become integral to the fabrication process, offering unparalleled accuracy and consistency in welding tasks. Their ability to work tirelessly around the clock ensures a significant increase in production rates, leading to reduced lead times and enhanced overall output.

Welding robots are equipped with sophisticated sensors and advanced programming, allowing them to adapt to various materials and intricate designs with utmost precision. This technological evolution not only addresses the challenges of skilled labour shortages but also significantly improves workplace safety by minimising human exposure to hazardous welding environments.

Manufacturers in the welding industry are attracting new talent through the integration of cutting-edge robotics and automation technologies into their operations. By incorporating robotic welding systems and advanced automation solutions, these companies not only enhance production efficiency and precision but also create an environment that appeals to tech-savvy individuals - our next generation of engineers.

By utilising robots and automation manufacturers are making available opportunities for future employees to work alongside state-of-the-art machinery, fostering a dynamic and innovative workplace. This approach not only addresses the industry's evolving needs but also positions it as an exciting and forward-thinking field, attracting a diverse pool of talent interested in the intersection of technology and manufacturing, thus future-proofing the welding industry.

As manufacturers increasingly embrace automation, the integration of welding robots marks a transformative leap forward in the pursuit of unparalleled quality and efficiency within the realm of precision manufacturing.

See one of KUKA's welding robots ?

KUKA: Our commitment to British and Irish manufacturing

KUKA Robotics UK Limited — 10/08/2021

KUKA is a strategic partner of the Catapult centres (UK), Irish research centres and many British and Irish universities. This helps to get more working, system-proven automation solutions into the hands of nearly every manufacturing industry.

The iconic image of the industrial robot is welding body-in-white panels on a noisy car production line, sparks flying. See beyond the car plant though, and robots are everywhere; packing product into bags, loading pallets, removing defective food from a conveyor, drilling holes in aircraft wings, blending sauces and soups, guiding parts to shop floor assembly points. Look further and more exotic applications abound: medical robots assist surgeons with complex surgery, cube robots pick customer orders in fulfilment centres, service robots help the infirm, milling robots carve statues, and so on. More niche and enigmatic uses are constantly being devised, as researchers also experiment with affordable collaborative robots.

How robots are applied by industry often begins in universities, at the lower Technology Readiness Levels, then in the higher TRL technology innovation centres – Catapult centres and others – where the new process is proven-out for commercial use. Britain and Ireland are especially good at both.

Every engineering-centric British and Irish university and the high value manufacturing research centres use robots in research. KUKA provides fully supported robots, integrated automation and consultancy to many of these institutions. KUKA robots are installed in 19 of the 30 universities making up the UK-RAS Network, a connected group of robot and autonomous system research funded by the engineering council, EPSRC. Examples include the Edinburgh Centre for Robotics, a joint venture between the University of Edinburgh and Heriot-Watt University, and Cranfield University, which has a focus on human factors, ethics and safety in Human-Robot Interaction. The work of UK-RAS spans applications from space and aerospace to bioengineering, collaborative robots, autonomous systems and more, underlining that robots in Britain and Ireland today have moved far beyond the car factory gates.

In Ireland, University College Dublin, National University of Ireland in Galway, Technical University Dublin and the other big engineering schools are doing similar work – see page 11 for an example at the University of Limerick.

Proving for industry, derisking investment

Industry often needs to trial a new process before it incurs the cost and risk of installing it in a factory, where it might not run optimally, or even fail.

The High Value Manufacturing (HVM) Catapult centres help both big and small companies experiment with new technology before they scale-up for production.

Robots and experienced engineers are available to trial processes over-and-over, like an advanced technology playground, offline to industrial operations.

KUKA robots are working in projects at six of the seven HVM Catapult centres. All four of the Advanced Manufacturing Technology Centre (AMRC)’s franchises, in South Yorkshire, North Wales, Preston and Broughton, have KUKA robots involved in research, as have Irish Manufacturing Research, CONFIRM and QUB in Ireland. Much of the research is for aerospace and non-automotive industry R&D, further proving that robots today have a much broader remit than automotive.

Speeding up aerospace manufacture

The VIEWS project at the Advanced Forming Research Centre (AFRC) in Strathclyde has helped Spirit AeroSystems increase the rate of cost-effective, non-destructive evaluation and testing of the geometries and material properties of composite components in aircraft winglets. This accelerated their manufacture and helped Spirit select the Glasgow-based facility as its European R&D base.

Working with an aerospace company, the team at Factory 2050 has commissioned an automated cleaning and sealing system, using a KUKA KR60 on top of a KMP1500 AGV. This project will eventually demonstrate the flexibility of robots when mounted to an autonomous platform that is able to navigate using Simultaneous Location and Mapping, aka SLAM, technologies.

Revolutionising logistics: Embracing the future with cobots

KUKA Robotics UK Limited — 13/02/2024

Collaborative robots are opening up new horizons for industrial automation in supply chains, benefiting enterprises large and small. One the most sought-after applications is robot palletising.

Palletising encompasses repetitive tasks, such as stacking goods onto pallets in a standardised manner. While crucial for the supply chain, these tasks usually don't demand high levels of complexity or specialised skills. As a result, despite managing high volumes, palletising is generally regarded as low-value work.

The ease of setting up such systems, often featuring plug-and-play functionality, consider the scmPAL Pro from SCM Handling, makes them highly appealing. Footprints for such cells are often reduced, cutting costs associated with extensive fencing and shop floor reconfiguration. But what if those benefits were further increased with the removal of fencing, completely, and the ability for workers to work in close, safe proximity to the robot palletiser?

Increasing efficiency and flexibility: LBR iisy cobot palletising

Maintaining a consistent level of performance across a shift can prove difficult for individuals and can lead to an increase in error rates. By integrating robotics within the palletising process, where consistency and repeatability are crucial, the accurate placing and stacking of boxed products can be maintained. But by going one step further and using a collaborative robot palletising system, manufacturers are able to benefit from a multitude of additional benefits, above and beyond process optimisation.

Quick to install.

One of the primary challenges perceived in robot automation is the downtime associated with integrating new technology into existing process flows. The relocation of fixed assets like conveyors, picking and packing benches, and storage units can be deemed costly. However, when introducing an automated robot cell that requires no fencing and boasts easy installation, these perceived barriers are soon put to bed. The LBR iisy palletising cell offers the advantage of precise positioning, aligning perfectly where it's needed for operation, in stark contrast to traditional industrial cells that demand a larger footprint and offer limited flexibility in installation.

Quick to commission

Set it up. Switch it on. Get started. The LBR iisy cobot, the key element of the iisy palletising cell, distinguishes itself with its user-friendly interface, facilitating quick and efficient operation without any prior robotics expertise. Integrated within a comprehensive turnkey cobot palletising solution complete with a lifter and vacuum gripper, the LBR iisy 11kg cobot can be swiftly deployed for tasks. Whether utilising the intuitive smart teach pendant or manual guidance, this cobot is designed for rapid and hassle-free implementation. With its versatility, the LBR iisy excels in various applications, notably palletising in this instance, where precision, speed, and agility are paramount.

Lower cost = faster ROI

Another common misconception about purchasing robots is their perceived high cost. However, the truth is, every investment entails a cost. When we factor in the substantial benefits to businesses—like streamlined processes, increased productivity, and enhanced quality—the initial investment appears modest in comparison to the potential returns. It makes sense that low-value tasks such as palletising are given to robots, freeing up human workers to focus on areas of the warehouse or factory where their skills can be more effectively used for the overall benefit of the business. Human labour is costly and whilst we need to continue to pay (salaries) for workers, only one initial cost is attributed to buying a robot. The LBR iisy is a cost efficient and reliable automation tool.
The LBR iisy palletising cell can also be leased.

Dynamic and easy to reconfigure

Rapidly changing manufacturing environments that produce customised goods in all manner of packaging iterations require automated solutions that can be quickly reconfigured to meet the needs of the business. In today’s ecommerce driven market versatility and flexibility are key. Multiple products can be managed through specific applications that can be changed quickly and efficiently in the LBR iisy teach pendant, either pre programmed or via manual guidance. The lift enables stacking at height and a vacuum gripper ensures that multiple package sizes can be accommodated*. The footprint of the LBR iisy palletising cell also enables strategic integration/installation where the technology is needed the most.

Enable seamless workflows between workers and robot

As the LBR iisy palletising cell requires no fencing and can operate in close, safe proximity to humans, warehouse or factory environments become more efficient. Highly dexterous tasks such as picking and order management can be managed by humans. Picked items can then be delivered to end of line automation (LBR iisy) for packing and stacking according to predefined programmes and optimised stacking sequences. While the cobot is attending to its palletising tasks, humans can continue to work around its immediate environment without compromising safety or workflows. Even when workers go on breaks or change shifts, the robot shall continue to operate.

To summarise

As the global population continues to grow, so does the demand for products. It's essential for businesses in the supply chain and logistics sectors, responsible for the movement and delivery of these products, to have the necessary technologies at hand to manage this increasing demand effectively. With an aging population and a widening skills gap placing immense pressure on supply chains and the wider UK industry, robotics and automation continue to emerge as indispensable tools in fast-paced, high-volume environments.

What does industry say…

“Up until now, robotics technology has not made a large impact in the world of logistics. This is about to change as advanced robots enter our warehouses, sorting centres, and even help with final-mile delivery. Logistics workers will benefit from collaborating with robots, while customers will see faster service and higher quality. Imagine a world where people can focus on work that is meaningful and more enjoyable. Picture a world where repetitive, tedious, or dangerous manual labour is uncommon. Dream of a logistics supply chain that is faster, safer, and more productive.” – Robotics in Logistics, DHL Customer Solutions & Innovation.

“The logistics industry is investing in meeting the skills needs of the future, however, due to the rapidly changing needs of businesses, the ageing population and a diminishing pool of EU workers, the sector continues to face challenges around the existing workforce, especially given the significant investment in skills necessary to help grow and decarbonise.
To prepare for future industry challenges, there is also a need for greater investment in infrastructure and innovation.” - logistics.org.uk, The Logistics Report Summary 2023.

To find out more about the LBR iisy palletising system, please contact: Michael.payne@kuka.com
*Assuming that package weight does not exceed maximum payload of the cobot.

Mobile Robots are Helping Farmers Harvest Apples

KUKA Robotics UK Limited — 28/11/2023

Labor shortages in agriculture, including fruit picking, have been a concern in various countries, including Germany, due to factors such as seasonal demand and changing demographics.

KUKA, DE and digital workbench have collaborated to produce a mobile harvesting robot to support fruit farmers during the apple harvest. The project will explore the further development of the interaction of KUKA' and digital workbench' equipment and explore synergies, especially with regard to apple cultivation.

In the future, the robot arms will move autonomously across the fruit fields in specific practical projects. The mobile and smart automation solutions of the two technology partners will then hopefully be widely used where previously harvesting machines with several harvesting assistants were used.

We can assume that harvesting robots will be used more and more in the future. The technology still needs to mature for large-scale use and the plantations also need to be planted in such a way that the harvesting robot can work efficiently.

KUKA's partnership with digital workbench is to develop a robot system that makes the most difficult tasks in agriculture easier. An automatic apple harvesting system that does not damage the crop is an important development in an industry that is dependent on seasonal labor.

Mitigating waste, which is costly for farmers is also a key consideration - In the UK alone £22 million worth of fruit and vegetables has been wasted directly because of workforce shortages in the first half of 2022 - The key therefore lies in automation.

The integration of automation in fruit picking and harvesting not only promises to significantly reduce waste but also stands as a transformative solution to address the challenges posed by the skills gap in the agricultural sector, ensuring a more efficient and sustainable future for fruit cultivation, on a global scale.

Read the case study in full, here

Learn more about digital workbench here

KUKA UK to Attend Appetite for Engineering, at the MTC, Coventry

KUKA Robotics UK Limited — 10/08/2021

Robotic automation: Productivity and Efficiency in the Food & Beverage Industry

Alongside Silver system partner OAL, KUKA UK will be promoting the features and benefits of robotics and automation along the food and beverage production process chain. Automated manufacturing gives rise to new possibilities for enhancing production: transform your processes to reduce costs, increase productivity and maximise flexibility with robotic batch production; empowering manufacturers by optimizing products, processes, and material flows; providing the tools to respond with agility and flexibility. The F&B industry is facing major challenges: new and creative solutions are needed in order to remain competitive in a global market, while at the same time providing consistently high quality.

A Look Back at 2023 : Keep on Moving into 2024!

KUKA Robotics UK Limited — 02/01/2024

2023 propelled us into an era of unparalleled efficiency and innovation.

The successful integration of cutting-edge automation technologies from KUKA has empowered many of our customers to achieve unprecedented levels of success. From optimised workflows to enhanced productivity, the impact of automation on our customers has been undeniable.

As we reflect on the triumphs of the past year, we eagerly anticipate an even brighter future in 2024. With an unwavering commitment to staying at the forefront of technological advancements, we are poised to bring about more groundbreaking automation technologies.

Our focus on refining existing automation solutions and developing new, tailor-made tools for our clients ensures that they are not just keeping pace with industry trends but are actively shaping the future of their respective domains. We are excited about the limitless possibilities that automation holds for our customers and are dedicated to helping them achieve unprecedented heights of success into 2024.

Take a look back at 2023 with us, as we celebrated 125 years of delivering automation excellence: https://www.kuka.com/en-us/company/iimagazine/2023/12/annual-review

Granta Automation Ltd, named as KUKA UK’s latest addition to their Platinum system partner portfolio

KUKA Robotics UK Limited — 04/03/2021

The system partner program enables KUKA to strengthen the breadth and depth of expertise available to its clients, via strategic partnerships that bring in-depth knowledge of applications and specialist skills to the benefit of customers across all manufacturing sectors.

For customers that need equipment integration and programming, what they bring is specialist skills, and knowledge of bespoke materials and geometries of products. KUKA’s sales force can talk about needs and introduce the specialist that have the skills to deliver the appropriate requirements and provide the best service and support.

One partner who has benefited from just some of the benefits attributed to partnering with KUKA UK, is Granta Automation, whose successes in the provision of end of line palletising, has seen them promoted from Gold, to Platinum system partner.

2020 has accelerated the adoption of automation and robotics across several sectors, such as food and beverage and logistics, due to ever-increasing product iterations, rising costs and strict social distancing requirements: industry is being forced to implement new, cost-optimized processes.

At the cutting edge of automated palletising, Granta’ industry knowledge and expertise, coupled with the highly accurate and repeatable characteristics of the KUKA robots, provides a versatile and flexible option for almost every palletising requirement.

Andrea Marsh, Granta Automation: “As a specialist robotic palletising company, we chose to partner with KUKA because of their high product quality. Having installed multiple robots, we have found them to be extremely reliable and requiring very little maintenance. Whilst they are not the cheapest robots on the market, the reliability and low maintenance saves our customers more money in the long run than having a cheaper robot with higher maintenance costs. Our strategic partnership with KUKA allows us to provide reliable palletising solutions for our customers”.

Bernard Bagley, Head of Robot Sales General Industry (UK) & Israel: ““The robot element of an automated system represents about 25%; integration, tooling and task-related software represent the other 75% and that’s the system partners area,” he explains.

“If you think of a palletisation robot, it picks things up, swings around and puts them down – it’s quite simple, really. It becomes complex when you add upstream and downstream functions, from conveyors to sorters and other pieces of equipment. KUKA is a product-based business and our robots are virtually 100% reliable. The wider system can be very diverse and it’s the likes of system partners, like Granta Automation, who are best placed to deliver in the application area.”

Whilst the UK still lags painfully behind its European manufacturing counterparts in robot density, the number of robots used within palletising applications in the UK, in 2020 rose by 140%, compared to 2019.

Andrea Marsh adds: “As a Platinum system partner we only see continued growth over the coming years. With the UK being well behind other countries in embracing robotic automation, there’s plenty of catching up to be done!”.

Working with KUKA often helps their system partners to ‘punch above its weight’; having the support of a large company can enable them to acquire business they might not otherwise.

Andrea Marsh concludes: “As a platinum partner we’re able to provide better training for our customers and internal staff. Aside from that KUKA are also a great team to work with, and as a key strategic partner for palletiser systems we look forward to a successful ongoing relationship.”.

Queen Elizabeth II

KUKA Robotics UK Limited — 09/09/2022

God bless the Queen

Subcontract rotary friction welding: an efficient and cost-effective means to joining a wide variety of materials

KUKA Robotics UK Limited — 10/08/2021

Subcontract rotary friction welding: an efficient and cost-effective means to joining a wide variety of materials.

There are several benefits to utilising a subcontract friction welding facility: established and proven expertise; utilisation of industry leading friction welding machinery; no need to invest in capital equipment; multiple component manufacture across numerous sectors; a range of geometries and material combinations can be joined; material, geometry, metallurgy and pre and post weld processing advice can be available.

Component manufacture is an important element within the supply chain and for consumers, understanding exactly where those components are made is an integral part of the purchasing process, and several factors will influence why a customer decides upon a supplier; product integrity, cost, availability, proven manufacturing process and reputation.

Subcontract Rotary Friction Welding: Cost-efficient, superior bonding, suitable for mission critical applications.

RFW is suitable for an immeasurable amount of applications where it is possible to rotate two components axially.

In the case of bi-metallic, copper-aluminium connectors, there is simply no other viable method of joining these two materials directly to each other due to the difficulty presented by them having very different thermal expansion coefficients. Low-cost aluminium is joined directly to high cost copper. Other than the obvious benefit of cost reduction by limiting the use of expensive oxygen free, high conductivity copper material, reducing direct costs, waste and the increased threat of theft are also reduced. Aluminium is the optimum mating material which does not impede conductivity and is useful for ease of crimping to electrical cabling. The electrical connector market for power distribution and rail is a significant market to benefit from this solid-state bonding process.

Other industries that specify RFW as their standard bonding method include the automotive sector producing axles, cv joints, turbo chargers, airbag canisters and other such safety critical components. The aerospace industry utilises the process for manufacture of landing gear shafts, steering shafts, ejector seat components and other high integrity components. The construction and yellow goods industry use friction welding for manufacture of piston rods and hydraulic cylinders where large diameter high quality steel chromed rods are joined to eyes, yolks and pinions for heavy duty industrial service.

Mining, oil and gas industries, manufacture drill pipes and rods for deep hole water boring, directional drilling, rock drilling and oil & gas (sour) service applications whereby the integrity of the joint is paramount as it can be performing under the harshest of conditions and under extreme compressive and torsional loads or percussive forces. The cost of failure in these components can literally cost the operators millions of pounds in lost revenues. The integrity of the friction welded bond is so superior to other joining processes by offering in many cases parent material properties, that most world renowned, OEM’s across these industries own and operate their own rotary friction welding equipment to produce their safety critical components in-house.

Cryogenic applications also benefit from the processes’ ability to join dissimilar materials. For instance, stainless steel to copper and interlayered transition joints consisting of stainless steel welded to titanium by use of an aluminium alloy interlayer to facilitate bond between the stainless steel and titanium which it is not suitable for direct bonding. Joints manufactured for this industry sector perform in very low temperature environments. Again, this is a unique benefit of the process, that these very dissimilar materials can successfully be directly bonded and operate in very demanding environments.

Friction welding has also proved very successful for welding tools, such as drill bits for example. Stronger than conventional welding, friction welded drill tools have an enhanced join integrity, as the weld is as strong as the parent material. This is vital for drill tools as they are commonly used at high-speed, so the weld must be strong enough to withstand dynamic stresses endured during drilling.

Friction welding has been used in the printing roller industry, decreasing production time and reducing product weight. This method allows the machining time on endcaps to be reduced, and eliminates the need for weld preparation, further decreasing production time.

Whatever the sector, or application in which the component shall be utilized, rotary friction welded products have proven to have an enhanced structural integrity.

The question that engineers and manufacturers ask when considering their production joining and manufacturing processes is can we do this better, cheaper and more efficiently?

The answer is ‘yes’ and the solution lies in subcontract friction welding.

Ten KUKA robots on tour in Europe with Belgian artist, Stromae

KUKA Robotics UK Limited — 27/03/2023

‘Alors on danse’ brought him worldwide fame. Now Stromae, Belgian singer, songwriter, composer is continuing his Multitude tour in Europe from March to December 2023. On stage with Stromae are Ten KUKA robots that move oversized LED screens. A video that has now been released across the globe shows how this spectacular stage set came about.

"The stars of this show are obviously the robots," Stromae pointed out in an Instagram video posted in July 2022, "they were the main inspiration of this show." Ten robots – five hanging from the ceiling, five standing on the floor – shape the show with their specially choreographed movements. In some sequences all the screens join together to form a kind of giant canvas, in others they form an arc of images around Stromae and his musicians or shine down on them from above. Video sequences can be seen on them, as well as light installations and a Stromae avatar that dances in sync with the living artist.

On his official YouTube channel, Stromae has published a video illustrating how the partnership between the artist’s creative label Mosaert and KUKA came about. The video highlights the contrasts of dazzling, international stage shows and German mechanical engineering, at its best!

Multitude Tour through ten European countries

KUKA is the exclusive partner of Stromae’s Multitude Tour, and March 4 marks the start of the 2023 concert year for Stromae and his crew in Bordeaux, which will take them through various cities in France and then onto other European countries. There are local dates in Belgium in Brussels and Rotselaar, in the Netherlands in Amsterdam, in Switzerland in Geneva and Basel, in Germany in Cologne and Berlin, in Great Britain in London and in Italy in Rome. Throughout 2022, the Belgian musician toured the USA and Canada, among other places. One highlight were his sold-out performances in New York on two consecutive evenings at Madison Square Garden, both with KUKA robots on stage, supporting the incredible stage show.

Robots are assembled and disassembled more than 90 times

By the end of his two-year Multitude Tour, the robots will have been set up and taken down more than 90 times. The stage set is dismantled in less than 24 hours and reassembled in the next concert venue. This is only possible if both the robots and the entire team in the background are flexible. KUKAs France subsidiary did most of this job behind the scenes. They advised the artist in advance of what was needed, gave the whole plan a structure consummate with the intense show schedule and are now the first point of contact when the robots need servicing. Two additional KUKA robots are on hand in the background, as contingency replacements and KUKA system partner, Paris based Vendôme, who managed the programming and choreography of the robots, will provide additional support where needed.

KUKA sets the entertainment industry in motion

KUKA can provide the entertainment industry with innovative solutions that meet the sectors’ specific demands. KUKA products feature at amusement parks, in creative art installations and at music venues and events.

To watch Stromae’s tour video, featuring the KUKA robots, visit YouTube: Mosaert and KUKA present the Multitude Tour.

Stromae's tour reaches Milan, Italy.

KUKA's industrial robots, formed the stunning digital backdrop

KUKA Expands its Autonomous Mobile Robot Line-up with KMR iisy

KUKA Robotics UK Limited — 02/11/2023

KUKA has added a new robot, the KMR iisy, to its autonomous mobile robot (AMR) line-up. This robot is designed for flexibility and reliability in demanding settings, making it an excellent choice for Industry 4.0 applications in production facilities and warehouses.

KMR iisy: Your Smart Manufacturing and Logistics Partner

The KMR iisy is a mobile cobot that can move quickly and safely in various workspaces. It's versatile and can be used at assembly workstations, in intralogistics, and as a robot service system. It consists of the LBR iisy with a load capacity of either 11 or 15 kg, and a mobile platform that can carry an additional 200 kg. The KMR iisy is also ESD certified, making it suitable for cleanroom use. It can be operated using the smartPAD pro teach pendant, eliminating the need for a second operating device.

KUKA's New Generation of Autonomous Mobile Robots

KUKA's new AMR generation sets the bar high for logistics 4.0, offering intelligence, flexibility, safety, and ease of use. These robots can be equipped with 3D cameras, safety laser scanners, or IP class 54 protection for reliable performance in various environments. They use differential drive for manoeuvrability and can autonomously adapt their routes for efficient navigation. They can charge themselves at a charging station or during work, and maintenance is easy thanks to large access hatches on the KMR iisy. The intelligent KMReS fleet manager simplifies integration, providing a cost-effective and safe solution.

These user-friendly mobile robots enhance (intra-)logistics processes, reducing both time and costs. They are beneficial for both large corporations and small to medium-sized enterprises.

Read more here: https://www.kuka.com/kmr-iisy

Watch the video here: https://www.youtube.com/watch?v=AZUGbXOR9s0

Robotic process automation and welding: delivering consistency, quality and repeatability throughout the weld process. But choosing the right automation partner is critical.

KUKA Robotics UK Limited — 04/03/2021

A conversation about buying a robot is just the beginning for any manufacturer considering automated processes. Identifying the right automation partner to deliver upon expectations is critical; one who will weave itself into the fabric of the customer during project delivery - strength in depth, high degrees of technical knowledge, customer empathy, and a commitment to delivering high end, proven solutions.

KUKA establish strategic partnerships with integrators that bring in-depth knowledge of applications and specialist skills to the benefit of customers across all manufacturing sectors. Bauromat, provider of automated arc and spot-welding solutions are recognised as one of KUKA’ go to solutions provider in the field of welding, utilising the iconic KUKA robot in several of their welding installations. Most recently Bauromat supported Stafford-based fabrication company Mec-Com, after a failed project install by another integrator left them discouraged and out of pocket.

Bauromat were able to step in and prevent the client from suffering any further loss of revenue, rectify all anomalies and complications, convincing the client of the benefits of robot process automation, through satisfying the original brief. Mec-Com are the latest company to introduce a fully automated robotic welding system, incorporating a KUKA robot, from Bauromat, within their manufacturing processes, and have since become an ambassador of robotics within manufacturing.

Mec-Com’s need for an automation system, like many manufacturers, was a result of increased throughput and a need to meet rising demand.

“Our clients approached us about expanding our welding portfolio and we had discussions about needing to upgrade to the robotic side of our processes”, says Mec-Com Managing Director Richard Bunce.

“We were new to the field of automation; we went through our normal procedure [to select a supplier] but we were not experienced enough to do a proper initial assessment. That’s the truth.”

Unfortunately, through not properly qualifying the original integrator, Mec-Com were delivered an automation system that was not only unfit for purpose, but entirely unusable, nothing more than a white elephant. And, this is a challenge faced by many manufacturers looking for a first step into automation. It can be an incredibly complicated process, full of technological jargon and new technologies. So how do you know exactly what to expect and how can you separate those true expert integrators with those that just claim to be?

“Automation solutions are not about selling a product in a box – anyone can do that,” says Brian Cooney, Managing Director, KUKA Ireland. “Until you walk the site and make a full technical assessment of what the customer is trying to do, you can’t help them, and sending any kind of estimate can be disingenuous.”

Richard continues “Take references. Go and speak to people and seek fair, unbiased advice. Do the research. Do the due diligence, make sure the integrator has experience in the field you are trying to integrate. Research them as a company and see and speak to their customers. That’s what we didn’t do. We didn’t do the due diligence correctly and that caused us a lot of pain”

With over 20 years of automation experience, generally focussing on the field of welding, Bauromat produced a report breaking down the issues with the current ‘system’, as well as proposing a system that would ensure that what Mec-Com needed could be achieved. But the report was worse than Mec-Com had initially considered.

“Unfortunately, what I was told was that it doesn’t work, it’s not just incomplete, but an unsafe system, and it’s extremely unlikely to ever function” says Richard.

The process links to Bauromat’ philosophy of integration from day one. In other words, from the first handshake to project install, Bauromat ensures that the end user understands the process, has visibility of the timeline, and has input and confidence at all stages. This allows a fantastic rapport to be built between supplier and user, making the final product the best it can possibly be.

“The robot element of an automated system represents about 25%; integration, tooling and task-related software represent the other 75% and that’s the integrators’ area,” Bernard Bagley, Head of Robot Sales General Industry, KUKA UK explains. KUKA is a product-based business and our robots are virtually 100% reliable. The wider system can be very diverse and it’s our integrators, like Bauromat, who are best placed to deliver in the application area.”

Kevin Kolkea, Area Sales Manager – Arc and Laser Welding added “The final weld quality is integral to the product and credibility of the OEM, in this case, MEC-COM. Choosing the right partners for their application was key to the project success. The TIG process proved to be the joining application of choice, providing best in class quality and aesthetics for MEC-COM. Bauromat, having the welding integration and tooling experience for this type of application, in conjunction with the KUKA robot for arc welding, achieved a highly repeatable joining process for MEC-COM”.

Richard concludes “We now have a solution, and robotics is a field we can get further involved in. The concept wasn’t wrong, we just picked the wrong partner.”

Revolutionising Whisky Production with KUKA's Robotic Innovation

KUKA Robotics UK Limited — 10/11/2023

In a world where Scotch Whisky is in ever-increasing demand, Chivas Brothers is making waves by automating the handling and palletizing of whisky casks. Using a KUKA industrial robot and custom end-of-arm tooling from SCM Handling, Chivas Brothers is tackling end-of-line palletizing tasks more safely and efficiently than ever before. This transformation is not just about efficiency; it's about reshaping the way they work, making the process safer, and increasing their production outputs. Watch the embedded video below to experience the future of whisky production.

Watch the video here:

Exponential Growth in the Whisky Industry

The whisky industry, including Chivas Brothers, is experiencing remarkable year-on-year growth. Chivas Brothers, one of three spirit process facilities within the company, handles new make spirit, which is transferred to casks for maturation.

Chivas Brothers and SCM Handling joined forces in 2017, with the aim of bringing automation to the whisky industry. SCM Handling, already experienced in brewing and cider industries, provided their expertise in keg handling, making them the perfect partner for this groundbreaking project. Their experience and knowledge in cask handling, specifically in whisky production, were essential to the success of this endeavour.

Eliminating Manual Handling and Working at Height

One of the key challenges in the whisky industry has been manual handling and working at heights, which pose safety risks. Automation has now made these risks a thing of the past. By reducing manual handling and working at height activities by 50%, Chivas Brothers can process and fill more casks in less time. Additionally, automation has allowed for the development of larger heavy goods vehicles, leading to reduced fuel consumption and contributing to Chivas Brothers' sustainability efforts.

The KUKA KR 700 palletizing robot is at the heart of this transformation. Known for its cost-effectiveness and low energy consumption, it is the ideal choice for forward-thinking companies.

Embracing Industry 4.0 and the Future

Chivas Brothers is committed to embracing Industry 4.0 principles, ensuring the whisky industry remains at the forefront of innovation. This transformation is not just about improving efficiency; it's about reshaping the way they work, making the process safer, and increasing their production outputs. The KUKA robot is the first of its kind in the whisky industry, heralding a new era in whisky production that prioritises both people's safety and the environment.

To fully appreciate this revolutionary change in whisky production, we encourage you to watch the embedded video above. Witness how KUKA's innovative technology is revolutionising an industry with a rich heritage and setting a new standard for safety, efficiency, and sustainability. The future of whisky production is here, and it's nothing short of extraordinary.