Smart & sharp: robots optimize blade transport

Automating the material flow, relieving the workload of employees and simultaneously increasing efficiency, flexibility and safety: these are the goals that have been achieved by razor blade manufacturer Wilkinson Sword with the aid of mobile robots. Packed with state-of-the-art sensor technology, GESSbots guide the sharp blades through all the finishing processes.

Wilkinson Sword GmbH has been producing its famous razor blades in the German ‘city of blades’, Solingen, for over sixty years. In keeping with the high standards of its long-established brand and its efforts to achieve a “product design and function that is perfectly tailored to consumer needs”, the company produces innovative shaving products here using top-quality blade steel that is subjected to punching, hardening, grinding and polishing processes. In the Solingen production facility, Wilkinson continuously strives to drive forward the digital transformation by automating repetitive manual work processes. Three so-called GESSbots – autonomously navigating mobile platforms (AMR) from W. Gessmann GmbH in Leingarten – have now assumed the task of transporting the razor blades between the grinding, cleaning and coating processes. In this production facility, the blades undergo finishing, whereby they are cleaned after the grinding process and supplied with a hard layer of chromium.

Qiun Fat Diu, Manufacturing Project Engineer, explains the background: “Before this step in automation, our employees used to push the transport carts and load the blades into the system by hand. Our goal was to improve the ergonomics for our operators and enable them to take on more value-adding activities such as quality control tasks, for instance.” According to Qiun Fat Diu, there is great acceptance among the workforce of the GESSbots in work processes: “The appealing visual and communicative design of the robots also plays a big part here. Our employees understand the great benefits to be garnered from these innovative robots and they have no reservations about their utilization.”

Gessmann and SICK – A successful partnership in automation

To implement this undertaking in automation, Wilkinson commissioned Gessmann, an experienced specialist in providing tailor-made platform solutions. Gessmann incorporated SICK in the project to provide expertise on all safety aspects. The two companies have a long-standing working relationship and have been intensively collaborating to solve the ever-changing challenges surrounding sensor concepts. SICK’s consistent expansion of its portfolio is reflected in the corresponding growth in the proportion of sensors in Gessmann products. Steffen Kuhnle, Project Manager for GESSbots at Gessmann, has been a part of this collaboration from the very outset and knows what is important in a good partnership: “SICK and Gessmann share great confidence in their partner’s respective high level of technological expertise and market knowledge. It is not only the products from SICK, but also its unique system approach with hardware and software alongside competent advice and service that enable us to meet the individual requirements of our customers.”

A complete package with state-of-the-art sensor technology

The automation solution at Wilkinson includes five passive transfer stations with a specially adapted holder for the customer's standardized material carriers. “The SICK safety sensors provide the GESSbot with the data to be able to navigate. With the support of SICK, Gessmann has packed the GESSbot with state-of-the-art sensors and control technology to ensure all processes function safely and smoothly,” explains Marcus Ichters, Key Account Manager Mobile Platforms at SICK.

“With the support of SICK, Gessmann has packed the GESSbot with state-of-the-art sensors and control technology so that all processes function safely and smoothly”

Marcus Ichters, Key Account Manager Mobile Platforms at SICK.

The workpiece carriers are recognized and differentiated with the aid of inductive sensors from the IME12 series. If the resource changes accordingly (new workpiece carrier), new orders are automatically created via an Ethernet interface and a GESSbot Gb350 is sent to this station via a new transport order. The robot identifies its location using the nanoScan3 EFI-pro safety laser scanner and docks precisely to one of the passive stations. Safe motion solutions from SICK ensure the protection of employees and the efficiency of mobile and stationary applications.

The safe position is monitored at the respective station using a transponder switch from the TR4 series. A DFS60S safety encoder checks the standstill. The protective fields of the safety laser scanner are then automatically switched so that no one can enter the danger zone of the lifting mechanism. The GESSbot has the appropriate structural design to pick up the workpiece carrier and transport it to the destination. Ichters also highlights the planned implementation of a safe 3D vision camera: “The safeVisionary2 continuously records the surroundings and monitors whether there is enough avoidance room if an obstacle appears. The GESSbot can then actively avoid the obstacle and return to its actual route.”

The GESSbot is also equipped with an additional Flexi-Soft safety controller, which communicates securely with the basic vehicle via the Flexi-Line bus. The safe end position for further travel is queried via an inductive safety sensor from the IME2S series. The project also includes a retrofit for elevator control so that the workpiece carriers can be automatically transported to another floor.

Satisfied partners produce satisfied customers

Steffen Kuhnle is very pleased with the successful implementation of the project: “Gessmann faced new challenges when it came to incorporating the GESSbots and the corresponding technology into the existing material flow infrastructure. We discussed the individual points together and SICK provided advice coupled with well thought-out solutions and products. This has enabled us to implement the concept perfectly at Gessmann. Collaboration is always on an equal footing and communication is excellent.”

The success and potential of this partnership has also made an impression with Wilkinson in Solingen. Qiun Fat Diu has had a very positive experience with the pilot application and three vehicles: “The system is safely up and running and has significantly relieved the workload of our employees. We have seen a large increase in efficiency and an optimization of resources in this area of material flow. For this reason we are working to expand the use of GESSbots and thus automate the entire material transport process. Extending their use to other areas of production is a step we consider to be entirely possible and one that makes perfect sense.”

These SICK components are used with the GESSbot (Home DE - GESSbot):

• Safety laser scanner nanoScan3 EFI-pro → NANS3-CAAZ30ZA1 - nanoScan3 | SICK

• Flexi Soft Safety controller → Flexi Soft Safety Controllers | SICK

• Motion control module MOC1 for Flexi Soft → FX3-MOC100000 - Flexi Soft | SICK

• Safety encoder DFS60S Pro → DFS60S Pro - Encoder | SICK

• Safe 3D-vision-camera safeVisionary2 → safeVisionary2 - Safe Camera Systems | SICK

• Inductive safety switch IME2S12 → IME2S12-04N4DC0 - IME2S | SICK

• Safe transponder switch TR4 → TR4 Direct - Safety Switch| SICK

• Inductive sensor IME12 → IME12-06BPOZC0K - IME | SICK

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