Robot-controlled transfer system developed by Fontys in collaboration with IXON

Fontys is the largest university of applied sciences in the south of the Netherlands, with more than 25 institutes in 10 different cities. One is located in Eindhoven, in the high-tech industrial area Brainport Industries Campus (BIC).

Here, a group of researchers, teachers and students from the Fontys College of Engineering developed a way to improve the efficiency of an already existing robotic production line using the IXON Cloud and IXrouter. The solution: a robot-controlled transfer system for the manufacturing industry.

We spoke with Randy Kerstjens, lecturer-researcher in Mechatronics and Robotics at Fontys, to learn more about the project and its real-world applications.

Can you give us a brief overview of your project?

"The manufacturing industry is becoming more and more automated and factories are getting smarter as robots perform tasks. We went a step further with project FLUFFY; (the) FLexible aUtomated Future FactorY. 

We created a production line and then upgraded it by adding multiple robots that not only assemble parts, but then place them in designated positions. This combination creates a more efficient and flexible production system that can be used in manufacturing, for example. 

The innovative aspect is the combination of robots working together that can feed and move parts or finished products to a transfer system with several workstations."Randy Kerstjens, lecturer-researcher Mechatronics and Robotics at Fontys

Why did you choose to work with IXON?

"With projects like this, the intention is always to work closely with the field. For project FLUFFY, we needed a remote access solution that was easy to work with, a reliable bridge between student and faculty networking activity for collaboration during a period when we could not meet in person. 

I had IXON previously used in my own company Concept Robotics, so I was familiar with its quick setup, intuitive platform and easy collaboration capabilities, so I asked them if we could use their all-in-one IIoT platform for this project. IXON wanted to participate in this. They understand how supporting research projects like this help shape innovative solutions of the future."

How did you guys test the concept?

"For this project, I worked with two students from the Adaptive Robotics minor within the Mechatronics department. The automated production system was developed and installed at the Brainport Industries Campus (BIC) in Eindhoven, where innovative, high-tech concepts for the manufacturing industry are made. The concept - from delivery of the individual parts to assembly and finally quality control - had to be tested on a Formula 1 car made of Lego. 

We built a small-scale production line with several workstations and created a setup in which an overhead loader was mounted on an Autonomous Mobile Robot (AMR). The top loader picked up Lego Formula One cart parts from one workstation, and placed them on the assembly station where a robotic arm assembled them. This process was monitored by a camera application developed as part of another graduate quality control project." 

"If an error occurs in the production line, the camera captures it and sends the defective part to another production line where it can be repaired."
Randy Kerstjens
Lecturer-researcher Mechatronics and Robotics at Fontys

What role did IXON play?

"In this case, we used the IXON module as a remote access solution. We simply set up a VPN connection to our system and began monitoring and - if necessary - debugging the system remotely. Using user management, we were able to add all project participants to the platform and provide role-based access control. This allowed us to make changes remotely and collaborate efficiently with colleagues and students - whether they were working from home or on site. 

In the near future, we plan to implement data logging as well. This will make it possible to collect, monitor and later analyze a variety of crucial data points to optimize production. 

If an error occurs in the production line, the camera catches it and sends the defective part to another production line where it can be repaired."

What are the real-life applications of this project?

"Practice-based research like this gives students the opportunity to combine learning with working on projects that have a real, demonstrable impact on the field. 

Within the manufacturing industry, the demand for advanced systems with a wider range of sequential tasks is growing. Our flexible robotic assembly system can automate much of the assembly and manufacturing process of a variety of products, such as cell phones, small (electronic) assemblies and pillboxes. 

As a result, companies are looking at the new production line of the future; with added operational value such as increased efficiency, more flexible production and minimized human error, as well as commercial value through new opportunities for collaboration within the manufacturing industry."

Sounds promising! What else are you going to do with this result?

"Of course, this is not the end of the project. We are learning from new developments in the field and other research being conducted, and implementing those learning points in our own project. In this way, we can further develop and improve FLUFFY, and continuously contribute to innovative solutions in the field - with strong partners like IXON on our side."