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Tag Archives: assembly

Production processes – factory automation

Pozostałe wpisy:

13 December 2022
28 October 2022
25 October 2022
1 August 2022

WIĘCEJ

Production processes are all activities related to the production of products. These include the gradual completion or creation of the expected product in accordance with the design or process assumptions.

 

Types of production

The production of products is linked to a value chain that includes supply, technological processes, transport and storage. Types of production can be differentiated by nature, location or volume.

Production lines

The organization of processes is arranged sequentially,where subsequent stages follow each other, finally giving the finished product. Production lines can be manual, semi-automatic or fully automated and robotic. Highly efficient lines are usually geared towards the production of one or several different products. Efficiency comes from the speed of individual processes, and the transformation of tools to different products affects volumes. Lines that are adapted to the production of different products must be equipped with additional equipment that will allow them to handle products that differ, for example, in size.

                                Production is flexible

An example of such a solution is a line for the installation of lighting lamps. On a conveyor with several different stations, you can put one of the many types of positioning trolleys, which are adapted to specific lamp sizes. In this way, production is flexible and more products can be added – all you have to do is design and manufacture a new typeofproduct.

                               Nest production

Nest production is a more flexible variant of a traditional production line. Individual workstations or process stations are not permanently bound by the flow of the product. This means that we can produce different types and types of products by changing the order of the stations. This type of production is possible if some technological processes do not have to follow each other.

                                Hi-runner

Our nest production concept has been applied to a factory in the furniture industry. We have unified all robotic stations, so they can be rearranged according to your needs. The most common products are manufactured on thehi-runnerline. On the other hand, all the others can be produced flexibly  by making  sockets in individual technological lines.

                                 Diffuse generation

Distributed production proved itself in the era of the pandemic, when various industries suffered from lockdown  or lack of raw materials. This type of manufacturing is not tied to a specific place. Based on 3D models, production can be subcontracted depending on the availability of human and material resources. This is where 3D printing and, for example, laser cutting work great. Distributed production allows you to save your own resources and make the customer independent of suppliers. New technologies  help to produce more and faster, but in this case the emphasis should be on the security of our data – i.e. digital libraries and data transfer, for example.

 

Production processes

Production processes

– mechanical – completing and assembling, twisting, assembly, cleaning, labeling

– chemical – gluing, dispensing  liquids and gaskets, UV curing, painting

– permanent joining of elements – welding, soldering

– machining – CNC, grinding

– testing – mechanical,pneumatic, electrical, EOL

– natural – resulting from the natural action of the forces of nature – drying, cooling, etc.

Production processes – preparation of raw materials, transport, packaging and palletizing.

How do we do it at Alnea? We have extensive experience in implementing production processes on automatic lines. The Horus 3D vision system developed by us allows for offsetting of production processes and additionally image analysis and control, which allows you to maintain the highest standards and key performance indicators – KPIs (Key Performance Indicators).

Need production line or robotic station? Contact us: office@alnea.pl

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Production lines – automation and robotization of production processes

Pozostałe wpisy:

13 December 2022
28 October 2022
25 October 2022
1 August 2022

WIĘCEJ

Manufacturing companies are now facing increasing demands on the speed, quality and customization of  the production of goods and goods. The last few years indicate an increasing need for changes and development of Polish companies. Integrators are getting more and more inquiries about production lines, which means that automation and robotization of production processes is playing an increasingly important role.

 

Production processes

Production processes are all activities that affect the production of products. They cover the  entire value chain – transport, storage, material flows and direct actions on the raw materials, components and details that make up our final product. An important element are also technological processes related to, for example, soldering, gluing, welding, cooling, i.e. in general physico-chemical phenomena to which the product or its elements are subjected.

Types of production lines

The pioneer of production lines is considered to be the American tycoon Henry Ford, who more than a hundred years ago organized production processes in one sequence. Although, in fact, the very departure from the manufactory forced similar solutions in production companies. Although the lines were created, they now cover all industries and thanks to them most of the goods available on the market are mass-produced.

                Manual lines

Manual lines are an organized sequence of processes in which all actions are performed by operators. An example would be, for example, a packaging line. At the conveyor belt on both sides there are employees performing on the koela activities – laying cardboard boxes, inserting furniture, spacers, screws and finally close the lid and palletize the finished package. Such a line can be efficient, requires an efficient flow of details and a large organization of employees who are basically irreplaceable in it.

                Semi-automatic lines

Semi-automatic lines are equipped with a conveyor system and equipment that helps with assembly or other processes. Such a semi-automatic line can be a production line of lamp assembly. Thepalletsbetween the individualstationsare slowly replenished  by operators thanks to automatic screwdrivers, testers, etc.

Semi-automatic lines can also have robotic sections, but between them there is always an operator station that performs some of the tasks independently

                Robotic lines, automatic lines

Automatic lines are a string of automatic stations that perform a programmed sequence of actions one by one. The operator only added components, received products and watches over the correctness of processes. Yes! With automatic lines, a human is also needed. Robotic lines are advanced manufacturing centers that, although quite expensive to buy, allow you to maintain quality and stabilize production.

               Assembly stations, test benches

Sometimes we don’t need a production line. All you need is, for example, an assembly station or a test stand. With uncomplicated applications, a properly designed human-operated station is not only more efficient, but also cheaper.

 

We build production lines

At Alnea, we have many years of experience in designing and building production lines, robotic lines, testers and assembly stations. We come to the customer, get to know his needs and requirements, and then we construct the entire machine from scratch. We have competence in the field of line construction and we recommend ourselves for cooperation. Here you can see what we have managed to create in 10 years.

Need production line or robotic station? Contact us: office@alnea.pl

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Automated assembly station

Pozostałe wpisy:

13 December 2022
28 October 2022
25 October 2022
1 August 2022

WIĘCEJ

A large part of the production is still carried out in manual or semi-automatic mode. The use of advanced machines is common for components or products with very high precision, but there is still little investment in smaller companies. Assembly processes can be automated, a small change can give a big effect in the form of more stable and accurate production. It also allows you to exploit the potential of the operator.

Which assembly processes are easy to automate?

The simplest assembly processes for automation are usually soldering,twisting, folding (e.g. plastic part of the housing). Of course, some products are manufactured in such a way that automation will be unprofitable, or simply the product requires human intervention in terms of accuracy, manual sense or visual control.

Other  processes  do not directly interfere with the product, but contribute to faster production – e.g.  transport, packaging or palletizing.

Assembly stations

Alnea specializes in the construction  of machines, production lines, but we also create assembly stations. Typical mounting stations can be purchased from many companies. However, we equip our stations with equipment according to the customer’s demand. In addition, we create production testers that increase efficiency and reduce losses associated with further processing of defective or non-compliant products.

 

Semi-automatic assembly

To move away from manual installation, we can use semi-automatic installation. This is a good solution when some processes are easy to automate and others require operator involvement. An example of this is the position where the employee pre-assembles the product and then the machines weld, foil and label it.

Robotic assembly station

Bentley among the production stations is a robotic assembly station. The operator’s task is to deliver components, and integrated robotics and automation systems perform all activities including packaging.

The use of the Horus vision system significantly accelerates the offset of production processes, including assembly processes. Our riveting station for  sub-gutter hooks  has been designed to reduce employee interference.

At Alnea we will design a assembly station for you for the construction industry,  automotive or electronics.

See what robotic assembly looks like

 

Need conveyor stsems? Contact us: office@alnea.pl

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New assembly line

Pozostałe wpisy:

2 December 2022
8 August 2022
18 March 2022
7 February 2022

WIĘCEJ

Our new application is manual assembly line. We’ve completed our first line for this investor over a year ago. The second semi-automatic line was equipped with a robotized station – the scara robot and the six-axis robot were integrated so as to collect the glass and screw it to the lighting lamp holder. It’s nice to enter a hall so unified in terms of production machines and equipment.

 

One line, many products…

The line consists of 7 modular stations, which is equipped with a conveyor belt and a return conveyor. Each of station is prepared for specific operations that employees perform so that a  product is finished in the last position.

Dedicated stands, on which lamps covers are transported in cycles automatically between the stations.  Well calculated tacktimes ensure that all operations are well synchronized.

Mission Impossible Integrator

Alnea is a technology company that designs and manufactures production lines, assembly lines and robotic stations. We have already created many such production stations, among others for sectors such as:

automotive,

electronics industry

construction sector,

furniture industry

and other.

Automations - intralogostics/h2>

Alnea is also a distributor of mobile robots. Automation of supplies and intralogistics in a company is an important part of investment. AGV autonomous mobile robots deliver details, elements and collect goods and bring them to the warehouse. One map of the hall can be used to determine many routes and the ability to call the robot when it is needed. Customized construction means maximum efficiency and quick return on investment.

Production line - designing, building, implementing

If the machine you are looking for does not exist on the market – you can be sure that we will build it for you. We will come, get research the process, requirements and simply design a line that will meet your expectations. Do you want to produce faster, maybe more reliably or more precisely – write to us!

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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Robotized assembly station within production line

Other realizations:

9 August 2022
22 March 2021
16 December 2020
3 November 2020

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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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COMPANY DATA:

ALNEA SP. z o.o.
Księcia Janusza 23/10
01-452 Warszawa

NIP PL 527-269-18-19
KRS: 0000456341
REGON: 146605974

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    KLAUZULA INFORMACYJNA

    Zgodnie z art. 13 ust. 1 i 2 Rozporządzenia Parlamentu Europejskiego i Rady (UE) 2016/679 z dnia 27 kwietnia 2016 r. w sprawie ochrony osób fizycznych w związku z przetwarzaniem danych osobowych i w sprawie swobodnego przepływu takich danych oraz uchylenia dyrektywy 95/46/WE (RODO), informujemy, iż:

    1. Administratorem przetwarzanych Pani/Pana danych osobowych jest ALNEA Spółka z ograniczoną odpowiedzialnością, ul. Księcia Janusza 23/10, 01-452 Warszawa.

    2. Pani/Pana dane osobowe przetwarzane będą na podstawie art. 6 ust. 1 pkt a Rozporządzenia Parlamentu Europejskiego i Rady (UE) 2016/679 z dnia 27 kwietnia 2016 r. w sprawie ochrony osób fizycznych w związku z przetwarzaniem danych osobowych i w sprawie swobodnego przepływu takich danych oraz uchylenia dyrektywy 95/46/WE (RODO) w celu związanym z realizacją zapytania zawartego w formularzu kontaktowym, w celu przesłania oferty handlowej.

    3. Odbiorcą Pani/Pana danych osobowych będzie podmiot świadczący usługi IT na rzecz Administratora z siedzibą na terenie Europejskiego Obszaru Gospodarczego.

    4. Dane nie będą przekazywane do innych państw i organizacji międzynarodowych EU ani użyte do profilowania.

    5. Pani/Pana dane osobowe będą przechowywane przez okres nie dłuższy niż jest to celowe, z uwagi na złożone zapytanie zawarte w formularzu kontaktowym.

    6. Posiada Pani/ Pan prawo dostępu do treści swoich danych osobowych, ich sprostowania, usunięcia lub ograniczenia przetwarzania, prawo wniesienia sprzeciwu wobec przetwarzania, prawo do przenoszenia danych, prawo do cofnięcia zgody w dowolnym momencie bez wpływu na zgodność z prawem przetwarzania, którego dokonano na podstawie zgody przed jej cofnięciem.

    7. Ma Pani/Pan prawo do wniesienia skargi do organu nadzorczego, gdy uzna Pani/Pan, iż przetwarzanie danych osobowych Pani/Pana dotyczących narusza przepisy ogólnego rozporządzenia o ochronie danych osobowych z dnia 27 kwietnia 2016 roku.

    8. Podanie przez Panią/Pana danych osobowych jest dobrowolne aczkolwiek konieczne w celu realizacji przesyłanego zapytania zawartego w formularzu kontaktowym, w tym przesłania oferty handlowej.

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