The Blue Star team deployed UR10 cobots to handle the task of copper tube expansion. Integrated with a vision system, the camera takes a photo of the shell and tube heat exchanger, detecting the profile of the copper tubes. With the help of artificial intelligence (AI), the center of each tube is calculated, and the coordinates are transferred to the cobot to guide it to the correct position. A specialized multi-gripper integrates a dispensing tool to apply sealant, as well as a drill that then expands the hole. The cobot is also programmed to dip the expansion tool in cleaner and lubricant every 5 cycles.

Stationing cobots in the company has enabled a safe space for people and collaborative robots to work in together. Human intervention lets employees supervise the process carried out by cobots, while also freeing up their time to handle other meaningful tasks that require human efforts. The cobot operators, who were upskilled to learn how to handle the cobots, are also excited about being able to use this advanced technology. “The manual process caused two types of stress: mental and physical. This is because the operator had to keep track of each and every pipe expanded, and the expansion process caused strain on the fingers. Now, operators are happy to use this advanced technology that has completely eliminated both types of stress,’’ says Yogesh Vakare, Senior Specialist, Manufacturing Engineering, with Blue Star Limited.