In an industry-renowned move, Harmon, a leading U.S. glazing company headquartered in Bloomington, Minnesota, has adopted cutting-edge robotics technology to revolutionize the installation of glass façade panels on high-rise buildings. The initiative, aimed at improving worker safety and operational efficiency, uses advanced robotic systems developed in collaboration with Raise Robotics and Universal Robots A/S.
Traditionally, the installation of fasteners required for glass façades involves workers hanging from the sides of skyscrapers, which presents significant risks and ergonomic challenges. Manual laborers are tasked with accurately aligning, drilling, and torquing brackets, often while suspended hundreds of feet in the air. Harmon, by utilizing robotic technology, seeks to transform this process into a safer, more efficient operation, eliminating much of the danger involved.
'Upgrading safety mechanisms in our processes has always been a priority,' commented Don Birmingham, general superintendent at Harmon. 'The robotics system enables workers to operate from safer positions, reducing their exposure to potential hazards without compromising productivity.'
The robotics solution integrates two UR20 collaborative robot arms from Universal Robots, strategically mounted on a mobile base developed by San Francisco-based Raise Robotics. These units are designed with a compact footprint for seamless integration, allowing for efficient deployment on construction sites. The robots’ energy-efficient design supports complete wireless operation, powered directly by batteries, thus eliminating cumbersome power cables.
Raise Robotics co-founder Gary Chen emphasized the practicality of their system even in challenging environments. 'The UR20's IP65 rating ensures robust performance in dusty, rainy, or extreme temperature conditions,' Chen explained. 'We've successfully operated the robots in temperatures ranging from -20°F to 120°F.'
The system, developed with extensive support from Universal Robots, incorporates resources like online technical documentation, dedicated engineering assistance, and active community forums, ensuring rapid troubleshooting and solution development.
Operational results have underscored the efficiency of Harmon’s new robotics system. Traditionally, installation of façade brackets required manual teams of two to four operators per site. The robotic system consolidates this, requiring only a single operator to oversee the process per location, thereby tripling the efficiency of labor allocation.
'We typically see a 3x increase in labor productivity with these robots,' noted Conley Oster, co-founder of Raise Robotics. 'This multiplier effect allows projects to reach a breakeven point for robotic investment by the completion of just 13 floors of installation.'
The precision of automated installations far surpassed manual efforts, with robots achieving placement accuracies within three-sixteenths of an inch, significantly reducing deployment errors. 'In manual setups, up to 30% of fasteners are incorrectly positioned,' Oster remarked. 'Robots provide greater accuracy, ensuring perfect alignment and enhancing overall build quality.'
Moreover, the system concurrently records data on torque values and alignment in real-time, a notable deviation from the sporadic quality inspections typical of traditional methods. Birmingham highlighted the advantage gained through this innovative approach, 'Receiving precise 'as-built' data enabled better advance planning for anchor placement, minimizing deviations before the glass walls were installed.'
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