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Archiwum dla miesiąca: October 2018

Automation becomes easier. Examples of implementations

We would like to thank for coorganization and presence KUKA Robotics – our partner of I-st Specialist Conference „Automation and robotization of industry”. Support of such important company is invaluable for us. Alnea has the status of Silver Systems Partner and has been cooperating with KUKA for years as specialist in the field of solutions integration. We can adapt the best applications, solutions and KUKA robots, so that our customers would receive ideally selected products that could give the best quality, utility and investment return.
A real partnership for a medal!

See how our training in Turin went!

Check out, how Alnea utilizes KUKA Cobots.

Łukasz Szczepkowski, Regional KUKA Robotics Sales Manager

Our guest was Łukasz Szczepkowski, Regional KUKA Robotics Sales Manager, who gave a lecture about really important subject: „Automation becomes easier. Examples of implementations”.

You were not there – regret it! But we have an on-line report for you!

During the presentation we saw several examples of successful implementations of KUKA robots. We were introduced to various classes of robots, which are the main point of implemented applications. Presented applications brought the customers measurable benefits, helping to save time, increase repeatability and eliminate/relieve possible station operators.

Watch the debate with Łukasz Szczepkowski

Our debate turned out to hit the bullseye. Discover answers to questions that bother companies. How robot service works? Is it true that a robot can function for 25 years?

See more here! Go to Alnea’s official Youtube channel to watch full conference stream.

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China International Import Expo – Alnea

Already on November 5 – 10th 2018 Alnea will present itself on the China International Import Expo. It’s a special event that president Xi Jingping patronage has taken his patronage over.

Alnea will appear with expanded presentation station.

Polish Agency of Investments and Trade has invited Alnea to prepare it’s own exhibition stand within Industry Pavilion, which will be created during the trade show. Participation of Alnea in this event is an exceptional occasion to present our achievements on the international arena. We wish for our company to make interesting contacts with trade agents, distributors and traders.

Within China International Import Expo there will appear Industrial Pavilions in a number of fields of high economic importance such as technology, biotechnology, electronics, pharmaceutics, automotive, food industry, cosmetics and fashion.

Polish Agency of Investments has reserved around 1000 m2 of exhibition surface, from which 160 m2 will be assigned to National Pavilion, in which we’ll see touristic and economic potential of Poland.

Strong representation of Alnea

Alnea in cooperation with KUKA and Blumenbecker is preparing a beautiful exhibition stand with area of 20 m2! We will present known on polish market vision system Horus and our patented soldering packet Zeus.

We wish for asian market to also discover our achievements.

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Why we don’t automatize?

Do we want to robotize? - rhetorical question.

We live in times when everything happens right now. There’s no need to wait a week for favourite TV show – we can just go to Netflix to watch whole season in one evening. We don’t have to stand in queue to submit a tax declaration – we fill a form and send it online. We don’t wait for a resupply of washing machines, opening of ticket office… Undoubtedly we have forgotten how much we’ve had waited in our lives. World without waiting for “something” has disappeared. Did we once imagined a world without waiting? Did we dreamed 20-30 years ago that our lives would really be “processed in real time”. It’s with the question if we want to robotize. Maybe we haven’t noticed that our washing machines, hairdryers, and ovens long time since have had artificial intelligence “sewn in” and vacuum cleaners, drones and cameras resemble visions of stage designers from sci-fi films. However buying a coffee machine integrated with our cellphone is something different than a robot in a factory. We buy a coffee machine as a consumer good, a gadget, which makes life easier, but also we can boast about it to our friends..

Why we don't robotize?

Our mentioned coffee machine will serve us along time – it will make coffee. But it won’t make money – that’s obvious! Unless we are an owner of a coffee shop… We treat appliances, technologically advanced ones, as a luxury. Why then are we afraid to investing industrial robots? Innovativeness of polish industry rises. However not as fast as we would like it to.

The reason for the slow automation and robotization process in our factories is first and foremost the fear of the unknown.

New machine..
Who will operate it?
Who will maintain it?
Where will I receive technical support?
What if I’ll have to change the process or the product?

But when you buy a new car do you worry if you can replace spark plugs?

No!!! That’s the purpose of car service. We treat problems the same way at Alnea. If you order a station or soldering packet from us, we will support you. We already have a lot of experience in this field. Distance doesn’t matter. We support our customers because we know that a satisfied customer means no complaints, good reputation and perspectives of future cooperation. Good systems integrator invited to cooperate is a source of excellent process solutions.

It’s not a cheap solution, but is purchase and implementation cost the only reason?

It turns out that the problem is rather complex. First of all we lack specialists with right qualifications. In system integration enterprises like Alnea, there are employed many visionaries of process and robotics virtuosos. They know how to refine, improve a process. But the most important people are in process of automation, right after factory management, are run maintenance engineers. It’s their knowledge and experience have impact on production, quality, they answer to challenges of quality and fluidity of process. It’s them who know the product best, its requirements, advantages and disadvantages. On their competences depends the future of a factory. It seems that, courses and rise of competences in teams is key issue when it comes to ability to robotize.

At Alnea we often invite to training, open days, capability test, to show a good direction of changes. Mangers and engineers with broad knowledge, ideas are a foundation of a company. Competences of a team should rise together with development of company. It’s worth it to invest in courses – they are a real support for complicated organism of a factory.

Making difficult decisions

What are other causes of the slow automation process? There are companies in which investment in innovations is a top-down decision of management. However in most production facilities in Poland it’s run maintenance engineers who pursuit manufacturing automation. How to convince superiors about necessity of adapting newest technologies to meet the demands of the market?

It happens that bosses of companies know about this need, but are afraid of taking responsibility for made decisions. In the end for systems integration or creation of a robotized line, a substantial sum of money is allocated, which is entrusted to a external company.

At Alnea we know what responsibility it is. We do our best to cut our coat according to our cloth and offers presented by us are backed with basic test of a production process. A convenient system of cooperation (budget or conceptual) makes us flexible in approach to customer.
Very big projects are also carried out with other companies. Such collaboration supports efficiency of realizing the project and assures feeling of safety of customers. It’s worth to risk to not only follow the demands of the market, but it’s even more profitable to predict global and our regional changes in industry. The vision of Elon Musk to send Tesla to space seems to be a crazy dream of a scientists.

However it shows us the way to the future where almost everything is possible and even risk is an investment good.

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Zeus – 100 Soldering Set

Zeus – 100 Soldering Set. Our concept, our invention… Controller for special assignments, excellent feeder and ergonomic soldering head – can be ordered form us.

Our guest was Jędrzej Kowalczyk, CEO of FANUC Polska

We had the pleasure to listen to the lecture: “First steps before beginning an investment – the concept, budgeting, time plan, choosing the technology”.

You were not there – regret it! But we have an on-line report for you!

During the presentation we saw several examples of successful implementations of KUKA robots. We were introduced to various classes of robots, which are the main point of implemented applications. Presented applications brought the customers measurable benefits, helping to save time, increase repeatability and eliminate/relieve possible station operators.

Part II of the presentation

See more here! Go to Alnea’s official Youtube channel to watch full conference stream.

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Warsaw Industry Week 2018

Already on November 6 – 8th 2018 the next edition of Warsaw Industry Week will take place. It’s worth to visit Innovative Industrial Solutions Trade Show to discover next novelties of widely understood industry and production.

What topic will Alnea present?

Krzysztof Kamiński, CEO of Alnea Group will conduct a seminar: „Human or robot – investment return from robotization, ROI versus TCA”.
We invite you cordially!
On November 7th 2018
Warsaw Industry Week
Industry Changes Leader Workshop
Workshop Hall No 13.

Przygotujemy dla Ciebie stanowisko automatyczne, półautomatyczne, zrobotyzowaną linię produkcyjną
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Automated soldering

Increasing demand for given product, miniaturization, decrease of manufacturing costs, increase of product quality, minimization of waste and elimination of human error are the main causes,k for which it becomes necessary to automate production processes, including soldering.

What do we understand as automated soldering?

Generally speaking, automation of soldering is about replacing an operator by a machine, which executes the soldering process. One of the soldering machine types is the 6 – axis industrial robot, integrated with a soldering packet – in that case we’re speaking about robotized soldering. The packet usually consists of soldering controller, solder wire feeder, soldering head and solder tip cleaner. Alnea meets the needs of the market and offers it’s own patented soldering packet Zeus.

Advantages of robotized soldering

Utilizing a robotized soldering process gives following possibilities and benefits:

1. Excellent repeatability and quality of solders – thanks to controlling soldering parameters (listed below) by a microprocessor, every soldered connection has the same shape, volume of solder etc. Robot never makes faulty connections i.e. cold solder or connects two soldering areas placed close to each other. Even such difficult applications as soldering flexible PCBs are executed almost flawlessly. Robot executing soldering program won’t miss any pad. Of course well trained operator with a lot of experience is able to provide high quality of soldered connections, but training of personnel in the field of soldering take a lot of time and money. Additionally, precise soldering is really tiring for a human so quality of his work drops with number of hours works within a shift.

2. Increase of production effectiveness – motion of a robot is faster and more optimal than of a human. Machine is capable to solder continuously 24 hours a day, 7 days per week, doesn’t need a break, doesn’t take a sick leave, doesn’t have to rest. All that ensures much higher efficiency than in case of operators’ work.

3. Possibility of miniaturization of soldered components – with use of the right soldering tip, a robot is able to solder miniature components. Thanks to high precision, soldering areas can be located close to each other. These features allow miniaturization of whole product.

4. Possibility of controlling soldering parameters – controller Zeus adjusts all parameters of soldering (listed below), thanks to that the process is perfectly adapted to given application. If a need arises , there is a possibility to modify online the parameters on the level of HMI of the robotized station. Thanks to dedicated technological packet Zeus for KUKA robots all soldering parameters can be changed and set directly through robot’s controller – in programming phase as well as in production phase. Precise adaptation of the parameters is especially important during lead – free soldering and in applications, in which soldered elements are close to each other and/or of small size.

5. Possibility of soldering in protective atmosphere i.e. nitrogen – in the process of lead – free soldering, it’s advised to use protective atmosphere of a neutral gas. Zeus controller has a built – in valve for steering the flow of nitrogen. Benefits of utilizing a protective atmosphere are: lower solder oxidation, and extended lifespan of soldering tip.

6. Constant efficiency – soldering robot executes operations with constant “takt time” so it’s easy to calculate efficiency and more importantly keep it at on a constant level.

7. Considerable decrease of the number of defective products – excellent quality described in point 1. brings along reduction of production waste. Elimination of manual transport and handling of delicate components ( i.e. PCB ) in robotized soldering process additionally reduces risk of creation of defects.

What decides on that solders made by a robot are of excellent quality?

In robotized soldering, soldering tip, solder wire and all the soldering parameters are adapted to given application.
Thanks to utilization of a industrial robot approach to a soldering point is realized with precision of hundredths of a millimeter.
Parameters of soldering process are repeatable and adjusted by the controller (primarily temperature, heating time and amount of solder wire).
Thanks to utilization of a cleaner connected to Zeus controller it’s possible to automatically and precisely clean soldering tip. The tip is cleaned by metal brushes and stream of compressed air.
Ability to solder in protective atmosphere i.e. nitrogen ensures decrease of solder oxidation and extension of soldering tip’s lifespan.
Program monitors work time and number of work cycles of soldering tip, thanks to which the tip is replaced before it’s spent.
Thanks to using an industrial robot, we are capable of reaching very high speed of approach to soldering point – in case of KUKA robots even 2 m/s.
It helps to keep correct shape of soldered connection.

In which industries soldering robot with Zeus packet can be utilized?

Robotized soldering packet Zeus is capable of soldering among others electronic components used in through – hole technology assembly, but not only. It can be use automate soldering in:
• automotive industry
• defense sector
• aviation industry
• electronics industry
• precision industry
• electrotechnical industry
• medical sector
• telecommunication industry and more.

What parameters of soldering process are controlled by a soldering controller?

Zeus soldering controller adjusts following parameters of soldering process:
• heating power
• temperature – there is a possibility to differentiate the temperature in different stages of soldering the same point (or area), what is not possible during manual soldering
• heating time of soldered area
• amount of fed solder
• speed of solder feeding
• amount of retracted soldered
• speed of solder retraction

If you are interested in robotized soldering with use of Zeus packet, contact us and find out, what solutions of soldering process we can offer for your company.

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