Przemysł Przyszłości – przekrojowy, inspirujący i praktyczny warsztat dla menadżerów przedsiębiorstw

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Archiwum dla miesiąca: November 2018


Automated line

Automated line consisting of 2 cooperating stations.

Station 1 is responsible for dispensing frames on conveyor belt (logic prepared for 4 types of frames), transport to 2 – axis manipulator (Pick & Place), constructed with FESTO components. Stop point below the Pick & Place is the most important spot of the station. In that location takes place pickup of connectors, which are delivered by WIBRAMET vibration feeder and placement of single connectors in dedicated holes in the frames. In the next step, on positioned connector, a nut is screwed on (from the bottom side of the frame). The nuts are delivered by WEBER vibration feeder and screwed on connectors with a integrated WEBER screwdriver. After fastening of necessary number of connectors (2-5, depending on type of frame), the product is transported further to station 2.

Station 2 is responsible for soldering process. The process is specific in way that the product before the start of soldering process has to be heated to temperature above 100 degrees Celsius. Whole soldering process is executed by ZEUS soldering packet (want to know more about our product – click the LINK) installed on arm of a 6 – axis KUKA robot.
After finished process, automatic separation of OK and NOK products takes place.

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NAL/NALF break switches tester

Tester of NAL insulated break switches and break switches with NALF breaker. The product is placed on a platform equipped with electromagnets that hold the product during tests. The platform is moved into sound – absorbent chamber, where the test is conducted. Test procedure is executed automatically. After start of the test, it’s not possible to open the chamber. Engaging one of three safety switches causes immediate stop of the test. In the chambers, there are two Delta servo drives, placed on balancers that allow fluid adjustment of drive’s position. The drive is put on an axis of break switch through a knurled bushing.

The test of the device consists of opening and closing the break switch fifty times. With each switching, drop time of knife is measured with a vision system based on Teledyne Dalsa cameras. The break switches also go through series of electric tests, among others: electromagnetic release test, main circuit insulation test, corona discharges test. Test software is coded in Labview environment, created by National Instruments.

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Production line – buffer magazine

The line has been prepared as buffer magazine after potting process. Line constructed by our company consists of 4 parts.
Station A is the station that begins production process. Within this station operator thanks to support of MES system receives permit to begin production depending on produced model. Station is the element that leads component to filling with resin in potting station.

After the end of potting process, the element reaches station B, which receives the elements and separates them, according to prepared logic, between 6 buffer conveyors (the line has been prepared to be expanded by additional 2 conveyors). Each of the conveyors is capable of storing up to 20 elements – station C. After finished resin drying process, the logic transports element to station D, where exposing the element for pickup by operator takes place.
Process has been based on components by OMRON.

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The law on support of new investments as a chance for development of the economy – WMSSE

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We thank for the co-organisation and presence WMSSE – our Partner of the I st Specialist Conference “Automation and Robotization of Industry”.

Our guest was Grzegorz Smoliński - President of the Warmia – Masuria Special Economic Zone

We had the pleasure to listen to the lecture “The law on support of new investments as a chance for development of the economy”.

You weren’t on the conference – regret it! But we have an online report for you!

Second part of the presentation

See more here! Visit the official youtube channel of Alnea and watch full stream of the conference!

Jeżeli potrzebujesz dedykowanego systemu wizyjnego
napisz do nas jak najszybciej: biuro@alnea.pl

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Warsaw Industry Week 2018 – Alnea

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On November 6 – 8th 2018, when our second team presented itself on China International Import Expo in Shanghai, Alnea together with other companies of Metal Machining Cluster, participated in important event on the map of polish industrial exhibitions – Warsaw Industry Week.

Display of our achievements!

The company presented it’s flagship products and carried out exhibit of implementations of robotized production lines.
In particular, the vision system Horus was met with great interest of end customers, but also manufacturers of robots. It turns out, that the system can be used not only for positioning a robot, but also quality control.

CEO of Alnea group, Krzysztof Kamiński gave a lecture: Robot vs. Human. Return of the investment, ROI vs TCA.

We thank very much all guests, our customers, Metal Machining Cluster and co-exhibitors. These were three energetic and fruitful days.

See you next year.

Jeżeli potrzebujesz dedykowanego systemu wizyjnego
napisz do nas jak najszybciej: biuro@alnea.pl

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Automation and Robotization of Industry – see online report of the conference

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More and more companies are interested in automation!

We didn’t expect that even the first edition of the conference would be met with such great interest. Besides a hall full of guests, we gathered a lot of viewers in front of TV’s, computers and smartphones. Live stream and videos have been watched by more than 20 000 people, which we consider a big success
Complete range of the conference in social media is over 80 000 recipients.
We received a lot of information that subjects touched during the seminar were helpful and displays of robots and devices unusually attractive.

Meet with Alnea!

We received many calls and emails from people and companies that because of many reasons couldn’t come to the conference, if they can come to Alnea and “touch” the automation. Of course they can! We encourage to send us an email to biuro@alnea.pl and subscribe to wait list for visit in our company. During meetings we prepare displays of our activities, discuss about Your goals and manufacturing challenges and help in starting processes of automation and robotization in Your companies.

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

The I st Conference “Robotization and automation of industry” ended with complete success. Unfortunately we couldn’t accommodate more applicants, but thanks to cooperation with the WM Group, whole event was not only transmitted on-line, but we also recorded the lectures, seminars and the debate. All the video material can be watched on the official youtube channel of Alnea!

Watch the lectures from the first part of the conference

Krzysztof Kamiński, CEO of Alnea Group
“Examples of utilization of robots in various branches of industry – from small to big implementations.”

Wojciech Łaś, Product Leader – Mitsubishi Electric Industrial Robots
“Is it worth to invest in robotization? Why ROI is not everything.”

Jędrzej Kowalczyk, CEO of FANUC Polska Sp. z o.o.
“First steps before beginning an investment – concept, budgeting, time plan, choosing the technology.”

Second part of the lecture.

Grzegorz Smoliński, President of the Warmia – Masuria Special Economic Zone
“The law on support of new investments as a chance for development of the economy.”

Second part of the lecture.

Jeżeli potrzebujesz dedykowanego systemu wizyjnego
napisz do nas jak najszybciej: biuro@alnea.pl

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Fanuc on the conference „Automation and Robotiztion of Industry”!

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We would like to thank for their presence FANUC – our partner in the I-st Specialist Conference „Automation and Robotization of Industry”.

FANUC for over 60 has been dealing in perfecting of products and continuous creation of innovations, which allow to optimize manufacturing processes. The subject of the presentation were intelligent technologies, among others robots and machine tools, CNC control systems and special options created to support manufacturers in the process of transforming current factories into factories ready to function in the era of Industry 4.0.

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.

Jeżeli potrzebujesz dedykowanego systemu wizyjnego
napisz do nas jak najszybciej: biuro@alnea.pl

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Alnea at the expo in Shanghai!

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Alnea in cooperation with KUKA and Blumenbecker has prepared a beautiful exhibition stand with area of 20 m2! We are presenting known on polish market vision system Horus and our patented soldering packet Zeus. We didn’t expect that Alnea’s products would be met with such big interest. Still the future belongs to automation and robotization of production processes.

Asian markets are discovering our achievements.

We have the great pleasure represent our country on the international arena!

Jeżeli potrzebujesz dedykowanego systemu wizyjnego
napisz do nas jak najszybciej: biuro@alnea.pl

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Automation of production processes

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Our company has been automating and integrating production processes for years. Answering invitations by manufacturing enterprises, we visit factories, in which components and products are manufactured. Some of them have multi million volumes, other are produced in small series. We assist in implementing solutions, which purpose is to improve quality of production, reduce number of standstills, errors and waste. For many run maintenance engineers the priority is the speed of manufacturing, other focus on excellent quality of precise devices and components.

Research and development – basis of modern automation

Analyzing our production automation implementations one can quickly reach a conclusion that currently emphasis has to be put on research and development of automation. Such requirements are imposed by reality, which slowly moves away from manufactures, in which in huge halls, on dozens of stations, stand hundreds of people soldering wires and assembling components by hand. Every factory is different, with different technical background, manufactures various elements, but every one of them faces the same future. Sooner or later they will have to automate even a part of their production. Such challenges appear also before systems integrators. How to find optimization of manufacturing, cost saving and investment return as beneficial as possible? In the current stage of development of technology we cannot delude ourselves – some tasks have to be performed by a human. Anyway, when talking with mangers of factories, we haven’t heard even once that personnel reduction is the reason for robotization. Currently the needs of industry are so big that employees perform jobs that can be robotized are required  for other tasks.

Automation is an investment!

Manufacturing is also described with one more characteristic, which is in fact it’s foundation. Creating certain goods, we are doing it because we want to sell and profit on them. Here however appear the aspect of competition, rivalry. Automation of production processes and it’s equipment it’s not only cost. It’s first and foremost an investment. This single magic word, behind which stand numerous zeroes on company’s bills, is however a ticket to highway of development and increase of capabilities and resources of the factory. On such highway there are companies, which have begun investing long time ago. However the fuel of development sometimes runs out and processes of manufacturing require a lifting. It happens for many reasons – mainly because progress requires miniaturization, change in design or new functionality.

Like cars that some time ago could fare our roads with speed of 120 and now 140 km/h.

How Alnea approaches automation processes?

Team of Alnea acknowledges necessity of constant investment, so we offer not only implementations of automation, but also improvement of functioning of already existing infrastructure, integration of machines, devices and systems. Revolution 3.0, which in many factories is a fact, in other only crawls on all fours. Varied development of different branches of industry is the reason that for many automation engineers vision of industry 4.0 – digitalization and management of manufacturing from a cloud is only a dream and for some an obvious requirement for meeting demands of current market. That’s why commit to projects related to technologies of the future. Sometimes our contractors even before signing a contract for automation and robotization of a line already reserve ability of access to the Big Data. That is the moment of contact of visionaries and hard realists.

The foundation is constant development

Exchange of experiences on trade shows, exhibitions and systems integrators meets is for us a source of inspiration, which repeatedly present in current trends in automation. Work of our engineers has twofold implications. While thinking about issues related to manufacturing and automation, we solve more general problems. The example is our patented soldering packet Zeus, which contains:

– controller, which will cope with most difficult challenges (i. e. soldering really small elements made of elastic PCB),

– soldering tin feeder – an answer to expensive counterparts of different manufacturers

– ergonomically shaped soldering head.

However portion of the problems in the field of automation and production systems integration are very individual cases for each factory or concern narrow spectrum of application of automation. Through teamwork we have, more than once found unique solutions.

Touching many issues in this entry, I would like to encourage you to visit our web page in search for inspirations, knowledge and maybe criticism that will motivate us to progress and rethinking anew certain questions.

Jeżeli potrzebujesz dedykowanego systemu wizyjnego
napisz do nas jak najszybciej: biuro@alnea.pl

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Robotized assembly station within production line

A very important project in the history  of Alnea was the project of building a production line for the valves for the ventilation system of car seats. One of the most interesting points of the automated line was station 1, which was designed for four KUKA robots working with a rotating production wheel, where the process was kept up, that is, without stopping the wheel. This solution reduced production time by 40%. An additional benefit was the use of 4 instead of the 5 robots required by the Customer, which resulted in a lower station cost.
Another station presents the cutting process, which thanks to the use of a variable geometry stamp reduced the noise level by about 20 DB, which was one of the key requirements on the part of the customer.

 

Soldering robot

The next process on the line is a soldering process based on our solution – ZEUS. The process ends with a video inspection.

At the next station you can see the process of plasmaming or preparing the surface for the application of glue. Note that the second tool on the robot is a dispenser that precisely applies glue.

 

 

The workpiece then passes to the piston (these are components such as springs and rubber bands with a diameter of 3 mm). A robot equipped with 3 tools is responsible for the process of cutting and assembling components with each other and in the next step passes the detail for the second robot, which measures the resistance and after the process is completed, transfers the detail for further production.

 

Plasma station

A cover is mounted on the next station, which is delivered via a vibrating feeder. After the installation of the upper bodywork is completed, the part is transported again to the plasma-adhesive station. In this process, the upper body and the bottom body are connected with glue. According to the customer’s requirements, the adhesive can not be lowered into the lower body, which is why in the next production phase a UV lamp was used, which within 4 seconds hardens the applied layer of glue.

A very interesting and complicated station in this production string was a leak and flow testing station. The tests were carried out using atmospheric air and helium. I would add as a curiosity that helium leak testing was at the level of collecting individual atoms, that is, at an almost laboratory level (in the production cycle of 12 seconds). The measurement results were developed in a dedicated LabView-based application. After the tests have been completed, the detail goes to the last station, where the product marking process (OK/NOK) takes place and is armed with a so-called dumper and handed over to the operator as a ready-made valve for installation or integration into valve blocks.

Summing up 14 robots, 3 shifts, 7 days a week, a minimum of 300 products per hour, quality assurance thanks to 10 video inspection points.

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