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Category Archives: Realizations


packing station

The furniture industry is implementing more and more automation solutions. After all, our region is a real woody basin and a paradise for furniture manufacturers. A leading company in the industry challenged us and on its behalf we prepared a packaging stand.

Packages with furniture

We analyzed 32 different packages of furniture in terms of individual elements that are in it – from furniture boards, fillings, fittings and spacers. We’ve also developed a clever way to put these parts in packages.

 

Horus – a flexible tool

The biggest problem in the packaging process was the way the elements were fed. They were stored on pallets without positioning. The robot as a tool is very precise, but blind. Horus – the eye for the robot allows for offset processes so that the robot could take plates and spacers directly from the pallet.

 

 

 

Factory 4.0

Robotic packaging was possible thanks to a set of tools. A Horus scanning head and a Schmalz vacuum gripper  are mounted to the KUKA robot arm. The robot scans the working field in 3D, the algorithm marks the individual parts, and the gripper takes them. This flexible solution allows you to take with one tool both furniture boards (regardless of color, shape or thickness), paper spacers, honeycomb spacers. Tacktime for individual processes was 6 s for individual parts of the packages.

Robogrant

At Alnea, we know how to automate with our heads. We also optimize processes in the furniture industry. We are also waiting for the announcement of the PARP – Robogrant competition.  It is to include support for furniture companies in the purchase of a robot. PARP has been conducting promotional activities for several months, but the competition has not yet been announced, and the deadline is still being postponed.

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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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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Production tester – project optimization and scalability

Other entries:

We have made a project   for a optical fiber production company. The manual test station was intended to help the operator to difficultly pass the correct marking and position of the fiber optics in the sockets. We have prepared the position for three different types of products – thanks to which the return on investment was shorter than expected.  The production tester designed by us ensured optimization and ergonomics of work and allowed for the scalability of the project.

 

Testing station

Our testers are designed to be simple and operator-friendly. The test station is equipped with an HMI touch screen, thanks to which the operator chooses the right model. The prepared ribbon is laid out in the  darkroom, and the other end is then pluged into the power socket. The closing of the darkroom  is verified  by  the  induction sensor because the quality of the test depends on the lack of external light.

The video sensor controls the order in which the fiber ribbon LEDs light up, allowing the operator to guide the product step-by-step through the testing process. Subsequent ribbons in the fixture A are postponed to fixture B in the correct order detected by the video system. The PLC management system,  in turn,  generates labels  which  ensures our  quality.

 

Quick application

The biggest challenge of the project was the high standards of the process, which had to take place in a complete darkroom, and then further steps should be done flawlessly. We know how important it is to maintain quality with a small number of NOKs. Our production tester was able to implement quickly, and a satisfied customer ordered another 5 testing stations.

If you are interested in purchasing production testers – contact us. We will make analyses, design and perform a production tester for you. We have experience in building electrical, electronic, vision system controll, pressure, leak and other testers.

If you need a dedicated vision system
write to us as soon as possible: biuro@alnea.pl

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LD-Series mobile robot – automated loading

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Automation of transport with mobile robots is gaining more and more interest in warehouses and production companies. We designed a flow rack in which automatic loading would improve the flow of details in the production hall.

Initial project of rack

The construction of the robot assumed the possibility of:

– load 4 cuvettes with the dimensions given above.

– draw and slide of the cuvettes

– installation of warning lighting

– mounting the operator panel

The robot was to transport between the flow racks – loading and unloading. The construction of the robot, equipped with a main control system, allows  to retrieve information from rack sensors and collect cuvettes in a given order.

When developing the solution, we wanted to avoid waiting for the actuator to be released in a place where there is no cuvette and the risk of releasing all the cuvettes.

Robot positioning

Robot positioning is an important aspect of starting a cuvette collection program. Robots LD series are autonomous and navigate themselves using the map and LIDAR. However, when approaching a potential obstacle, they stop avoiding a collision. Using the magnetic tape, we were able to guide the robot to the right path and improve the robot’s positioning to +/- 1 cm.

Energy management

Automatic loading, controller and actuators draw energy from the robot’s battery. This is where the essential aspect of energy management comes in. The charge-to-work ratio of the robot is 1: 4. This means that one hour of charging should be enough for 4 hours of work. In practice, we also use other current receivers, and in addition, a high load makes the robot’s battery discharge faster. Depending on the shift system, we can load the robot, e.g. at night or take advantage of production breaks – e.g. during team shifts. We can also charge the second battery and replace it when necessary, which is a short and easy process.

If you need a dedicated vision system
write to us as soon as possible: biuro@alnea.pl

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Visualisation of production space – new dimension of 3D plant

How to transform the old hall into a new production space. Drawings of designers, however, do not reflect the nature of the place and its possibilities. That is why the company director invited us to cooperate.

From the beginning…

We sent two employees to the factory, whose task was to know the customer’s needs and the characteristics of the place. We made photographic documentation, took dimensions and detailed information about machines and devices that would be in the new hall. Then in a few weeks we made a static 3D mockup in Visual Components taking into account the order of production processes. It took us an additional month to add dynamics.

New reality

The intelligent factory, although it did not yet exist, was available in VR glasses. Anyone willing could enter the digital world and look at the new hall, working production machines and robots transporting components. Visualization allows you to assess the pros and cons of the designed factory and significantly affects the decision-making process. It also has an additional plus – it helps to find investors.

One service - two products

As part of the consulting service, in addition to visualization in virtual reality, we also made a promotional film. The whole is a great solution in terms of a rational approach to investment. It allows you to correct errors before the implementation stage and assess the strengths and weaknesses of the implementation. Adopting the right business model is the basis for the transformation towards Industry 4.0.

 

 

If you want to see how your factory might look or you are wondering about the potential of your company - contact us! biuro@alnea.pl

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Automatic assembly line for multiports

The line is used for automatic assembly of adapters and semi-automatic assembly of multiports using pre-assembled adapters.
The line consists of two stations:
1 station – installation of adapters in multiports,
2 station – automatic assembly of O-rings on adapters

Robotized srewing

At the first station, the operator is responsible for assembling multiports and supplementing components in Wibramet vibrating feeders. The housings are placed in a rotary turntable rotating 180 °. While the Mitsubishi RV-4FR robot takes the gasket with a nut and screw them into the multiports, the operator completes the second fixture. Turntables are located on two sides of the station and can be used simultaneously depending on production needs. The ASG SD2500-50FX screwdriver is equipped with a specially designed tool for picking and tightening nuts with gasket.

Automatic assemlby of adapters

The second station is equipped with vibrating feeders and an automatic system of applying O-rings to the adapter and o-ring lubrication. The adapter is lifted by a positioning socket into a gripper connected to the Festo pendulum drive. Than the adapter is inverted.
The operator’s task is to supplement the components for vibrating feeders in accordance with the messages on the HMI panel.

Ergonomic production line

Work on the line is sedentary. The station has been adapted to the related safety requirements. The stations are equipped with Keyence safety curtains. Process control is easier due to HMI (Human-Machine Interface) operator panels, located at station 1.

Panels allow you to start or stop line operation, directly control line elements in manual mode, and display information about errors and warnings. You can also access error logs and user logins from the HMI level. The processes are supported by the Balluff vision system.

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Robotic station for riveting gutter hooks.

Robots for construction industry? Such a surprise was visible on the faces of most people who had the opportunity to see the position during the construction. The station with two robots and a conveyor is designed for riveting gutter hooks, packaging hooks in cartons and palletizing. Here is our robotic riveting station.

Harmony of robots and an excellent vision system. Watch how it works!

Robot KUKA has that power.

The station is equipped with a vibrating feeder and rivet positioner, which are moved to the press. The station also has a plate positioning area. The plates are completed by the operator throwing them into the litter box. The Omron vision system takes a photo and means properly arranged plates that the KUKA robot takes and positions and puts on the prepared rivet.

3D positioning system for 6-axis robots - Horus

The second KUKA robot is equipped with 3D positioning system – Horus – you can read more about our vision system here. It scans one of two places prepared for pallets with hooks supplied by the operator. Appropriate algorithms facilitate picking the hook from the box without the need to position the details first. The robot translates the positioning hook before placing it in the press. This is an important process due to the large variability of hook bends and dedicated holes for rivets.
After collecting all the hooks from one layer, the robot takes a separator, removes it through a properly designed dump and starts scanning from the beginning. After selecting the hooks from the given palette, it starts the process on the second palette.

Automated riveting

The rivet with the plate is taken by a 2-axis manipulator and then deposited on the press matrix. On the matrix, the rivet and metal plate set is held by means of a vacuum suction cup and then the hook is attached to the set by a robot. The whole is mechanically connected by means of a press and an appropriately profiled punch.

 

The finished hooks are inserted by the robot into cartons that differ in dimensions. The next layers of hooks are secured with cardboard spacers. The station is equipped with a feeder with appropriate presence and type detectors.

What is the role of the operator?

The role of the operator is to replenish hooks, plates, rivets, spacers and cardboard boxes. When refilling most components, open the station door. The access doors are equipped with appropriate safety jumpers. The door must be closed again by the operator.

HMI

The machine can be operated via the operator panel with a clear and intuitive menu. With the help of our HMI, you can control the work of robots and machine elements in manual mode, as well as access to production statuses and user logins.

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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Robotized assembly line for satellite TV tuners

Robotized assembly line for D – profiler frames or die cast housings with PCBs with use of an automatic screwdriver and solder elements in place with use of Alnea’s Zeus Soldering Set and Horus Vision System 3d Positioning For Robot .
Elements’ transport inside and between line’s stations, screwing and soldering processes are executed by three 6 – axis robots. Line is equipped with Balluff safety systems and a safety cages, preventing interference of outside conditions or a third party.
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Suited for client

The line is equipped with two types of dedicated box magazines. Both types have adjustable width and depth to accommodate various components.
Robot picks die cast from the box magazine and moves it under thermal paste dispenser to put the paste on the designated spots.

Three robots – complex assemblye

VEKL0005 line consists of two stations:
1) storage and preparation of components equipped with robot KUKA KR6 R900-2
2) screwing (KUKA KR6 R700-2) and soldering station (KUKA KR3 R540)
Die cast housing or D-profiler frame assembled with PCB in station 1 is placed on one of two fixtures integrated with linear drives by Station’s 2 manipulation robot. Elements are held in place by a set of pneumatic actuators during screwing process.
Die cast is moved into screwing position where PCB is screwed to the Die cast housing with an automatic screwdriver integrated with 6 – axis robot. The robot picks screws from an automatic feeder.


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Collaboration of robots

After screwing process is finished, elements are moved into soldering position where connectors’ pins are soldered to the PCB. Soldering process is executed by station’s second 6-axis robot integrated with Zeus soldering equipment.
Zeus’ controller through which the soldering process can be adjusted is located in a cabinet on the front side of station’s A safety cage.

Alea Vision System - Eye for the robot

Finished product is removed from the fixture and placed in a box magazine on the storage rack in station 2 by the manipulation robot.
Components are handled by a robot equipped with a set of Festo grippers and Horus vision system.
Station’s robot scans the rack with Horus vision system to verify proper placement of box magazines and components inside them.

What does operator?

Operator’s task is to monitor the process with use of the HMI panel, refill screws through dedicated chute and place box magazines with components in proper spots on storage rack, monitor handling of components by the robot and remove box magazines with finished and NOK products.

What we can do for you?

What we can do for you? We can design and build production or assembly line. Alnea products guarantee innovative solutions and high precision of manufacturing with use of highest quality, repeatedly tested materials.

We will prepare for you an automatic, semi-automatic, robotic production line. Ask us about Horus Vision System!
write to us as soon as possible:

biuro@alnea.pl

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Assembly line for lighting fittings with the robotic station

The assembly line consists of eight stations, including seven production stations. The robotic station (6) is equipped with a scara robot and an OMRON six-axis robot. Manual stations (2-5) are equipped with control boxes and emergency stop buttons. The line allows manual or automatic operation. The specified cycle time is indicated by appropriate traffic lights.

Modular stands

The stands are connected by a modular and automated belt conveyor. Positioning pallets designed for three different product sizes are set on the conveyor. Elevators (1 and 7) and the bottom conveyor ensure efficient return transport of the stands.

Each station is equipped with control buttons enabling operation in automatic mode, in which the appropriate time is foreseen for each activity. The stopper is released and the conveyors are started in accordance with the time specified for the given operation. In manual and automatic mode, the operator can pause the conveyor and turn it on again. Additional two-handed buttons activate elevators to return the stands.

Line work cycle

The line work cycle can be divided into two alternating parts – process and transport. In the process part, operators perform operations on bindings located on stands. During transport, the stands move between stands. The transport part also includes the movements of elevators at the end stations. Work at the automated station is performed automatically by industrial robots.

Collaboration of robots

The automatic station is equipped with two Omron robots. The six-axis robot takes a lid using pressure grippers and places it on the housing. Scara collects corners, screws and bolts both parts. The adapted HMI screen facilitates process control and production supervision.

When creating our production lines, we use matched components from well-known manufacturers:
IGUS, KIPP, FESTO, OMRON, ELESA+GANTER, BALLUFF, HIWIN, SIEMENS, SMC

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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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