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Archiwum dla miesiąca: March 2021


Automated soldering

Pozostałe wpisy:

Our Zeus  Soldering Set is getting more popular. We receive inquiries from France, Uk, Czech Republic, Hungary and Bulgaria. So far, we have been implementing soldering automations mainly on traditional six-axis industrial robots.

Today we are proud to present automated soldering together with collaborative robot for the first time.

Last year we sent Zeus Soldering Set to the Osnabrück University of Applied Sciences to the robot lab of Professor Rokossa. On of Prossors’s Rokossa students, Mr. Lennart Kurze, wrote his Bachlor thesis about the integration of Zeus soldering set together with the drag&bot robot operating system and the UR5 cobot from Universal Robots.

 

 

Using the drag&bot OPERATOR PANEL to define the cobots position

drag&bot

drag&bot is a graphical robot operation system for various industrial robots and peripheries. In its portfolio drag&bot supports the use of robots from brand like ABB, KUKA,  Yaskawa or FANUC. The software is very intuitive and user-friendly to use.  In addition, the system supports grippers  from all major manufacturers such as Schmalz,  Schunk  and  Robotiq, as well as vision system from Balluff,  Cognex and Sick.

Use of drag&bot

drag&bot is used in five steps:

  1. Connect Hardware: Robot and soldering set are connected to the Industrial-PC via Ethernet connection
  2. Configure Hardware: In the COMPONENT Manager the basic settings for the hardware is defined
  3. Program Robots: With the BUILDER a robot program sequence is created based on Function blocks (e.g. “move robot”)
  4. Set Parameters: The settings of each function blocks are defined by using graphical – WIZARDS
  5. Run Program: The robot program can be directly tested in the OPERATOR COCKPIT

 

Image 2: Use the drag&bot Trajectory WIZARD to define the robot path

drag&bot

How to prepare programm in drag&bot.

  1. Connect Hardware: Robot and soldering set are connected to the in all IIndustrial-PC via Ethernet connection
  2. Configure Hardware: In the COMPONENT Manager the basic settings for the hardware is defined
  3. Program Robots: With the BUILDER a robot program sequence is created based on Function blocks (e.g. “move robot”)
  4. Set Parameters: The settings of each function blocks are defined by using graphical parameterization – WIZARDS
  5. Run Program: The robot program can be directly tested in the – OPERATOR COCKPIT

Soldering with cobot

The soldering process itself is quite easy to automate. Some components – for automotive, precision electronics or special purposes must be soldered by six-axis robots. However, more and more a soldering application are done by cobots. Using the drag&bot robot software, we now have the ability to implement applications faster and at a lower costs, because – the software can also be operated by worker or technican without extensive robot training. Soldering with cobot also allows us to move the arm “hands-free” mode – so the positions can be quickly adjusted for new applications or product variations.

Research

In his Bachlor thesis Lennart Kurze from Osnabrück University developed a prototype, in which he was implemented a soldering cobot from Universal Robots (UR) with Alnea soldering controller – Zeus using the drag&bot platform as middleware. Unitl now, Alnea integrated all Zeus controllers with on robots themselve. Cobots used for soldering is an interesting technological solution, that is increasingly required in industry.
For the application above, Alnea provided the the communication protocol of the soldering device, which allowed Mr Kuntze to develop a function block for drag&bot using the of Python programming language. The function blocks allows to direcly communicate with the soldering controller, to set e.g. the, solder head or trigger the tin feeder. Thanks to Mr. Kurze’s work, integrators now will be able to configure Alnea’s soldering device themselves using the drag&bot software.

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Automated soldering with drag&bot

Automation

Process automation is becoming easier and more accessible for integrators and end-users. Simplifying program development  and robot operation is a key component of drag&bot.

Soldering automation includes elements such as:

– precise temperature control

– automatic feeding of the exact amount of tin

– mechanical cleaning of the tip

– possibility to add a vision system

– repeatability of the process

Collaborative robots

Collaborative robots working with man or cobots open up a new perspective for production and preparatory processes. Of course, the soldering cobot integrated into the drag&bot platform will still need additional safety measurements, however, it is worth considering this option, which optimizes the production processes in the company.

 

The Alnea Group would like to thank

Lennart Kurze

 for his contribution to the development of the Zeus Soldering Set, for the development of new communication methods and the expansion of the portfolio of robots integrated with the Zeus controller. Mr. Lennart Kurze’s commitment, extensive knowledge and professionalism deserve recognition.

Thank you for your cooperation and we wish you professional success in the future.

 

 

If you would like to receive an offer for the modernization of a production or assembly line
write to us as soon as possible: biuro@alnea.pl

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OUR PARNERS

Bet on industrial robots – 2020 summary in Alnea

Pozostałe wpisy:

When the crisis was hanging in 2019, we feared the collapse of bitcoin, the difficulties of Brexit and possibly customs wars. But no one expected the nightmare of a global epidemic like the one 100 years ago to return to the 21st century – schools, shops, museums and factories. Uncertainty about the future is the most unfavourable conditions for economic development. After all, Polish entrepreneurs have handled the situation quite well. Many companies have focused on robots, thanks to which they have implemented new machines and invested profiteerly in production.

 

Come back with shield

War time wishes to come back with a shield, not on the shield now have a double meaning. State aid proved to be needed due to the heavy burden of the tributes to Fiskus and the ESM. Our company benefited from the support which helped us survive the most difficult months.

New production lines/h2>

We could not complain about the lack of orders this year. Production lines, robotic stations and testers, which is basically the majority of our portfolio went to customers from all over Polish.

In 2020, the Alnea team made new implementations:

– 4 advanced factory visualizations

– 1 production line with robotic workstation

– 1 assembly line

– 1 repair line with industrial robots

– 5 production testers

We also visited 36 companies, prepared and executed many offers, testing solutions for our customers.

New production lines/h2>

We could not complain about the lack of orders this year. Production lines, robotic stations and testers, which is basically the majority of our portfolio went to customers from all over Polish.

In 2020, the Alnea team made new implementations:

– 4 advanced factory visualizations

– 1 production line with robotic workstation

– 1 assembly line

– 1 repair line with industrial robots

– 5 production testers

We also visited 36 companies, prepared and executed many offers, testing solutions for our customers.

AiR Conference/

Our Conference – Automation and Robotics of Industry this year has already had its 3rd edition. Despite the restrictions and difficulties, we managed to organize a safe and interesting event, which was attended stationary by 72 people, and the online broadcast reached 20,000 (!) people on the day of the broadcast. The AiR conference is a meeting with the production companies of our region with distributors of automation, robotics. The best speakers presented fruitful robot implementations, the idea of Industry 4.0 in the factory of the future, digital kanban and improvements that give real savings.

 

 

Relief for robotics

We look forward to 2021. We are waiting for the promised relief for robotization. More and more small businesses are buying robots and implementing them on their own. This gives hope for the development of the Polish economy and increasing the potential of our production companies.

That’s why we have prepared a surprise for you – from January 2021 we will publish short videos in which we will present interesting solutions to the technological problems that we have had to face in our integrative career.

Tech me robot!

"Road to Success" Award

The culmination of our year-long struggle was the 1st prize in the Road to Success competition. The competition is implemented by the Agricultural Advisory Centre in Brwinow. The  award was presented with congratulations to Krzysztof Kamiński, President of Alne, by Andrzej Duda, President of the Republic of Poland himself.

The Marshal of the Province – Gustav Marek Brzezin, Voivode – Artur Chojecki also sent their congratulations. It is a great distinction and a commitment for the future.

 

If you would like to receive an offer for the modernization of a production or assembly line
write to us as soon as possible: biuro@alnea.pl

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Industry 4.0

New technologies are evolving faster and faster. Multi-device integration, streamlining production processes and overriding control is a priority in Industry 4.0. This idea was created as a response to China’s strong development in the field of innovation. The basic principles of Industry 4.0 are the use of artificial intelligence, advanced data processing and human collaboration to increase production efficiency and minimize losses.

As part of the Future Industry Competence Center project in 2019, Alnea designed and built the Demonstrator Factory of the Future. Such a project requires interdisciplinary knowledge, knowledge of many technologies in the field of robotics, automation, mechanics and IT solutions.

Industrial robots and machines

At Alnea, we already have a whole stable of robots that we pride ourselves on. They are usually useful for production tests. Our customers very often send us inquiries about technological possibilities. We perform technological tests on products – gluing, soldering, scanning, video inspection, gluing, applying paste, sealing, welding and others.

 

Our robots

KUKA KR6 R900-2 – a great robot with long range and good payload. It is ideal for applications with our video system because we use the entire arm range to receive a scan of a large working area

Kuka KR6 R700-2 – nevertheless than the previous one – an excellent robot for testing or e.g. assembly. Used in this application due to the smaller range dictated by the small cell to which we put it.

FANUC Robot CR-7iA/L – long-range, low-load collaborative robot – perfect for pick&fingers

OMRON LD-60 – AGV – autonomous mobile robot with a payload of 60 kg. For the transport of electronics – just in time.

SMT OV1385 Renex TWS AUTOMATION – SMT line for automatic surface installation is a great example of how you can integrate the cooperation of many machines.

Factory 4.0

The implementation of the process chain in Our Demonstrator’s Factory 4.0 started with the Fanuc CR7iA robot. He downloaded the PCB and put it on an AGV mobile robot with a customized body. The robot then transported the plate to the SMT line, where the electronic components were surface-mounted. After sintering in the furnace, the plate was moved to a specially added frame on which two KUKA robots were mounted.

 

Robotics

The first robot was equipped with a Zeus soldering  kit and a Horus vision system. The video system is also a 3D scanner – it checked the board and then sent it to the second robot under the worktop coordinates. The THT (Trough Hole Technology) technique assumes that the through-hole elements are on one side of the plate and the soldering field on the opposite side. The second robot mounted the elements “from below”, while the robot with the video system soldered them “from above”. After the inspection scan, the plate lowered the production line.

Industrial Demonstrator 4.0

The Industry 4.0 demonstrator served as a model for many cloud computing technologies. The entire mini-factory was hooked up to a top-down management system associated with the database. Additionally, production could be initiated remotely. The camera located in the corner of the demonstration room allowed you to remotely track all production processes.

 

Automation and robotization of production processes

Automation and robotization of production processes is now a desirable development direction for companies that want to stabilize production, also due to a pandemic. Alnea has many years of experience in designing and building new machines for industry. We also create:

– production lines

– repair lines

– automatic lines and semi-automatic lines

robotic stations

– positions with soldering robot

production testers

Automation

Automation of production processes was implemented by us in such industries as automotive, electronics, construction and intermediate industries. We encourage you to contact our automation and industry 4.0 experts.

Construction industry can be also automatised! If you want to receive an offer for a robotized position - write to us! biuro@alnea.pl

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Tech me robot!

Pozostałe wpisy:

Technologies and machines gathered in Alnea allow us to develop new products, research and development, test new production solutions. We have already implemented more than one hundred different automated lines, robotic stations, production testers. We have a lot of experience in the field of automation, robotics, machine design. That’s why we decided to share our knowledge. Cycle “Tech me robot”. We have adapted the robotic room at Techroom Alnea and especially for our customers, supporters, enthusiasts and hobbyists on our You Tube channel we put short videos about different technological solutions.

Techroom - everything you want to know about AiR

Accelerating innovation development and new products in the Automationa and Robotics (AiR) market make us have huge hardware capabilities. However, there are many processes that require dedicated solutions. Techroom is a great place to test new solutions.

You can watch the first episode of Tech me in the Alnea Techroom below.

Robot soldering

Tech me is the knowledge of automation in a small pill. Recently, we have received a lot of inquiries about soldering robots. Zeus is a Alnea production controller that is ideal for robot soldering. Everything you would like to know about soldering automation can be found in the video below.

Positioning and offset

Do you know this pain when valuing deployment when a large part of the budget is absorbed by sensors, positioning and video cameras? We went through it too. That’s why we’ve created our own system that replaces hardware. Positioning and offset in one device mounted to the robot arm – this is our Horus, of course.

And about our video system episode 3 Tech me.

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Instead of webinars

We recommend the Tech me series. Instead of hour-long webinars, you can watch interesting facts from our Techroom while waiting for the coffee water to boil … Don’t forget to subscribe to our YT channel. Thanks to this, our latest videos will not be missed! Do not forget to subscribe our YT channel!

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If you would like to receive a new or refresh the old offer for a difficult time of crisis
write to us as soon as possible: biuro@alnea.pl

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Production lines – design and modernization

Pozostałe wpisy:

Market requirements are increasing, production needs to be better planned, energy efficient and scalable. Alnea  also has the design and modernization of production lines in portfolio.   A well-planned, well-planned and successful on-site implementation can be the beginning of a longer cooperation, and whose roles of the client and contractor cease to be the basic determinant of the relationship. Cooperation on some projects is rather a partnership based on trust. No one wants to invest in expensive machines without a guarantee of success. The proven integrator is not only a production line supplier, it is also an advisor, tester and technological support.

 

Manual workstations

In a company producing lighting elements such as lamps and fluorescent lamps, we have implemented an assembly line. Manual workstations connected by a conveyor were adapted to different products – from quite small to large ones. We also designed a second twin line, but with a robotic position – to compare different process characteristics.

The collection and analysis of valuable data is a feature of Industry 4.0. We don’t always have to buy the most expensive technologies – sometimes a well-thought-out data collection system is enough – as in Factory 4.0 or tailored to kanban production. Our engineers will help you choose the right solution using your experience.

 

Production line design

We have also been asked to  analyse product manufacturing in  depth – including component  deliveries. The recommendations allowed the board to decide on design changes. It would be unprofitable to build completely new assumptions, so we started looking for savings in the automation of individual production processes or the way components are supplyed. The changes were  not  critical – they mainly consisted in redesigning themold for casting, and contributed to a lot of  savings.

 

Modernization of the production line

Today, many companies invest in automation and robotics or are looking for solutions in the field of Industry 4.0. You don’t have to buy new machines. Alnea  proposes a simple solution, which is the modernization of the production line. We will come to you, take measurements, analyze the process and product, and then offer you several different modernization options. Contact us – we will choose the right model of cooperation for your needs.

Industrial automation

If you are wondering whether industrial automation is a good solution for your company, please visit Alnea. We share knowledge, advise, test – we are here for you …

If you would like to receive an offer for industrial robots, cobots, mobile robots
write to us as soon as possible: office@alnea.pl

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