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Because they come in a wide variety of styles and types, choosing the right one for the job can be confusing.
We've outlined some of the basics below. If you have any questions, contact one of our product specialists for more information.
What is Modular Automation?
Modular automation represents the next frontier in factory automation, where production lines can be divided into mobile modules that can be quickly reconfigured for various purposes. This article explores the advantages of modular automation and highlights how smaller, lighter, and battery-operated motors can enhance its capabilities.
In today’s rapidly changing manufacturing landscape, businesses face increasing pressure to adapt swiftly to shifts in labor availability, environmental conditions, and global trade disruptions. Many companies are embracing automation to boost efficiency and safety, such as automating part transportation and hazardous area operations. Additionally, the trend toward modularization is gaining traction, allowing production lines to be tailored to meet specific demands.
The key to addressing these challenges lies in achieving "layout-free" automated equipment and production lines—a cornerstone of modular automation.
What is Modular Automation?
The term “modular†refers to smaller components of a system that can be rearranged. This concept can apply to production lines, manufacturing plants, or even products themselves. "Automation" implies tasks performed autonomously with minimal human intervention.
"Modular automation" signifies the next stage in factory automation where production lines can be broken down into mobile modules capable of being reconfigured for different purposes. Imagine each module as a wheeled Lego piece, carrying equipment for various tasks and easily integrated with other modules. For instance, a production line that usually packages apples could be reconfigured to package pineapples.
This flexibility enables the same production line to cater to different needs, allowing factories to respond instantly to real-time demand changes. The highest efficiency is achieved when all production equipment is modularized and self-propelled by autonomous mobile robots that communicate wirelessly and are managed by AI.
Benefits of Modular Automation
The ability to repurpose the same production line for different processes improves productivity while conserving space, energy, and labor. The outcomes include greater cost savings, faster time-to-market, and reduced downtime.
One significant advantage of modular automation is the freedom to design layouts without constraints. This flexibility supports high-mix, low-volume production, helping address labor shortages and save both space and energy. The resulting cost savings and quicker market entry make modular automation highly appealing across industries.
There are two primary types of modular automation: semi-mobile and fully-mobile.
Semi-Mobile Modular Automation
In semi-mobile modular automation, some components are fixed while others are modular. Mobile robots transport parts automatically between modules, enhancing production efficiency by eliminating manual part transfers. A mobile robot with a small turning radius can operate efficiently in confined spaces, improving spatial utilization.
A semi-mobile modular automation line features certain modules fixed to the floor. By integrating mobile robots with some conveyor modules, parts can be transferred autonomously, boosting efficiency by removing the need for manual transfers. Such a setup can function effectively in tight spaces.
Take a look at the image below showcasing a semi-mobile modular automation line:
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Fully-Mobile Modular Automation
In fully-mobile modular automation, every module is powered by mobile robots, allowing each module to move and reconfigure itself automatically.
From Layout A to Layout B
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By modularizing and mobilizing the entire production line, maximum flexibility is achieved, enabling customization for diverse needs.
The table below compares "semi-mobile" and "fully-mobile" modular automation. While the U-shaped line in semi-mobile modular automation is fixed and immovable, the modular production line method (fully-mobile) offers more flexibility and can even add new units to meet additional requirements.
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Supporting Modular Automation with Modular Automation-Compatible Products
For engineers looking to embrace modular automation, it is recommended to consider battery-powered, smaller, lighter, and smarter motors and drivers. Standardizing on the same product technology across all motion axes can also reduce the learning curve. Manufacturers have started offering products that meet the "modular" criteria.
"Modular automation-compatible products" are a group of products sharing the common concepts of battery drive, compact size, and light weight. Ideal for mounting on self-propelled devices and mobile equipment, they contribute significantly to the realization of modular automation. Similar to modular production lines, modular automation-compatible motors, actuators, and drivers can be mixed and matched for various purposes.
At present, Oriental Motor’s modular automation-compatible products include the AlphaStep AZ Series family of DC-input stepper motors, linear actuators, hollow rotary actuators, and mini drivers, along with the BLV Series R Type DC-input brushless motors and drivers. These products support industrial communication protocols such as EtherNet/IP, EtherCAT, Profinet, CANopen, Mechatrolink, CC-Link, SSCNetIII/H, and Modbus RTU.
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Product Utilization Examples with Modular Automation-Compatible Products
Articulated Arm Type Transportation Robots
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For precise positioning tasks, consider the AZ Series Absolute Stepper Motors or Actuators with mini Drivers. Oriental Motor’s AlphaStep product family now features a battery-less mechanical absolute encoder. Additionally, the AZ Series mini driver is designed to be compact and lightweight, maximizing cabinet space utilization.
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For speed control or basic positioning, the BLV Series R Type Brushless Motor and Compact Driver offers excellent performance. Recently, the BLV Series expanded to include the "R Type," featuring slimmer brushless motors and much smaller drivers that accept battery power. Key features and functions remain consistent with the original BLV Series, including ramp operation and low battery operation.
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Product Utilization Examples with Modular Automation-Compatible Products
Articulated Arm Type Transportation Robots
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For articulated arm type transportation robots, the AZ Series Stepper Motor (with mini Driver) is a great choice.
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Lifting and Lowering Type Transportation Robots
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EH Series Gripper (with mini Driver)
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Conveyor Type Transportation Robots
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L Series Rack & Pinion System (with mini Driver)
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Belt Conveyor
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Transportation Robot Wheels
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AGV Application
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Tips for Selecting Motors
To ensure a motor works optimally for your application, begin by using our online motor sizing tool to calculate the necessary torque, inertia, and speed values. Add a safety factor to account for unknown sizing parameters, then search for a motor meeting those requirements.
If assistance with motor sizing or product selection is needed, contact our technical support team.
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In conclusion, modular automation is revolutionizing the way we approach factory operations, offering unprecedented flexibility and efficiency. With the right tools and products, businesses can achieve their automation goals while staying agile in a dynamic market.