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Tag Archives: industry 4.0

Automation Systems Integrator

Pozostałe wpisy:

28 October 2022
25 October 2022
1 August 2022
28 June 2022

WIĘCEJ

In Alnea, we design, build and implement robots, production lines, assembly lines, robotic stations. As an integrator of automation systems, we create non-standard solutions – EOL testers, prototype machines for automotive, electronics, construction, furniture. We implement Industry 4.0 in companies.

 

 

 

VR visualization

VR visualization helps us design the solution down to the smallest detail from the planning stage. We create virtual factories, digitize processes or build a digital twin.

 

Production lines

Our largest production lines were created for automotive. Stations connected by one process are used to produce valves that you have in the seats of your cars if you drive a Volvo or Audi.

 

 

Assembly lines

Assembly lines were ordered from us by companies producing lighting. 4 different automatic lines, semi-automatic and robotic, are used for the assembly of street lighting lamps. We adapt our lines to flexible production. Special positioners adapted to different dimensions of lamps allow for quick changeover.

 

EOL Testers

Testers are an important part of production. First of all, they increase the efficiency of the production line, but also save components, energy and time. As a system integrator, we have prepared, built test benches based on leak testers at the level of helium atoms. Our latest testers improve the work of installers in the production of fiber optic connectors.

 

We build machines

Yes, we build machines and custom solutions.   Our potting buffer takes over the resin-flooded diecasts, directs them to the right place on one of 4 different transport lanes. The resin solidifies in 24 hours, and after this time the finished elements can be picked up from the warehouse. We know that production is variable so we left room for 2 additional belts that can be expanded with the machine.

 

 

Robotic stations

We adapt our robotic workstations to the needs of our customers. 3 such station solder and assembly  TV tuners in the Czech Republic. And another robotic station gutter riveting hooks for a leading Polish roof manufacturer.

 

Industrial robots

We have been integrating industrial robots for more than 10 years.  We have already implemented KUKA, Mitsubishi, Omron, Fanuc, Yanome robots,  as well as mobile robots and Unoversal Robots cobots. A robot is just a machine that needs the right tools and optimal processes. That’s why we’ve created tools for robots:

– for soldering,

– Horus vision system,

Together with Schmalz , we have developed a Horus furniture packaging system and a special gripper that allows for flexible processes.

We have already integrated 72 robots and have experience in robot tooling!

 

Industry 4.0

The idea of Industry 4.0 requires many educational, popularizing and promotional activities. We created two demonstrators of  the industry of the future, and also conducted 3 rounds of training for managers. We implement Industry 4.0 and, as a system integrator, share our knowledge with others.

Need vision system or packing robot? Contact us: office@alnea.pl

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Research and development

Pozostałe wpisy:

28 October 2022
25 October 2022
1 August 2022
28 June 2022

WIĘCEJ

The development of new technologies is the foundation for the creation of more effective and advanced products or services. Implementation of innovations in everyday life – Smart City, medicine or  industry are strategic changes that shape modern society and affect the economy. Research and development is currently one of the most dynamically growing areas.

 

The Silent Revolution

Economic and social changes are usually associated with unrest and rebellion against technology. The silent revolution or digitization is playing out before our eyes. Waste management systems, light management centers, digital administration, e-prescriptions are just some of the unnoticed facilities that we use thanks to innovations, i.e. products and services created by research and development departments.

Research & Development

When Krzysztof Kamiński, the CEO of Alnea, received the Vector for 2018, the Jury justified the choice asfollows: “The efforts of the Alnea Group have been appreciated for introducing technologies into our lives, which recently we could only see on science-fiction films. For harnessing virtual reality to design, implement and supervise advanced automated production lines. ”

You would think that the whole of Alnea is a department of research and development.

B&R

Alnea started by creating production lines and assembly stations for the automotiveindustry. However, the more machines were created, the more  one key element was missing – a device that would provide vision for our robots. The B&R department was created to create such an eye for a robot. As a result,  we ran the project  “Automatic system of optical positioning in the space of anthropomorphic industrial robots” as operating within a fund  1.1.1.for which we received funding from the National Centre for Research and Development (NCBR).

 

How to create a research and development department

The answer to the question “how to create a research and development department” is not at all obvious. First of all, the most important thing is the goal – that is, what we want to achieve. Whether we want to change an existing product, create a new one or create a center for solving technological problems – the goal determines the direction, but the important, and actually the most important, is the foundation, i.e. people with specific competences. Technologies will grow like walls on this foundation, and they will be connected by a goal defined at the beginning. This is how a permanent “building” is created, i.e. the integration of human and technological resources.

Project management

Creating new technologies and implementing innovations is like managing a project whose goal is defined, but it is not always known whether it is achievable. Teams often face a variety of challenges that are not always easy to identify – such as the current lack of semiconductors on the market. That’s why our R&D team is so diverse – to deal with adversity in the most creative way.

B&R team at Alnea

Research and development is an area where automation and robotics integrators are really good, although it’s not so obvious. And yet designers, automation, robotics create prototypes, test possibilities, look for solutions.

B&R team at Alnea

– Krzysztof Kamiński – CEO and visionary

– Marcin Kamiński – CTO and inventor

– Michał Brejnak – PM, unofficial Scrum  Master  😊

– Sebastian Górski – Master of automation

– Emilia Rybaczyk  – Mother of robots

Need suppert in Resaerch and development? Contact us: office@alnea.pl

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Automation Integrator

Pozostałe wpisy:

28 October 2022
25 October 2022
1 August 2022
28 June 2022

WIĘCEJ

Automation integrator is a technology company that integrates various components of automation, robotics or electrics. In fact, the scope of activity of integrator companies is much wider. Customers typically ask such companies to design a production line, robotic station, or machine with specific specifications. A good system integrator is also suitable for upgrading machines or integrating IT systems and machines at different levels – that is, in typical Industry 4.0 applications.

 

Where to start automation?

There is only one answer to the question of where to start automation. We start with the product! We analyze all materials and processes from the moment of ordering raw materials or components to the departure of the finished packaged product. What is important here is the way in which the components are fed (e.g. whether they are packed and fed in bags, feeders or trays) and all component activities and material flow. The integrator can look at these processes with a professional eye and find so-called  bottlenecks so that it can propose a new solution.

What is not worth automating?

Based on today’s technologies, almost anything can be done. But what is not worth automating? For sure what does will not have return of investment. Activities requiring agility of human fingers or visual inspection of man in some cases are better left to operators and assembles. On the other hand, repetitive operations such as twisting, soldering, packaging are best suited for automation and usually have a shorter payback time.

Quotation

Offering is the entire process of learning about customer demand. It includes not only the price, but also the specific solutions that the system integrator presents. The offer price consists of different parts such as:

– automation concept

– design and construction of structures, electrical, pneumatic, mechanical systems

– control and electrical cabinet

– ready-made automation components purchased from distributors – sensors, systems, security

– other machinery forming part of the contract – tooling robots, adhesive dispensers or gaskets,

– external expertise

– additional costs – accounting service, fuel, hotels, machine transport to customer.

 

 

 

 

Integrator like inventor

Most of the machines that make up engineering companies are basically inventions, actually prototypes. The whole complicated relationship between the ordering party and the contractor should be based on safety buffers. This means that excessive indicators (e.g. 100 % effectiveness) are in principle unattainable.   The integrator should behave professionally informing the client, and not accept kuntilde order to just keep the company.

Tough industry

System integration is a difficult industry that requires knowledge in many fields. It is impossible to be a specialist in all technologies, so sometimes engineers will only get acquainted with it in the purchase technology, and yet it still needs to be implemented and communicated with other systems.

Challenges

The challenges that await integrators continue to grow, as do the challenges facing manufacturing companies. A good partnership is the foundation for joint success. At Alnea we offer transparent, long-term cooperation. They have already trusted us – IKEA, Kongsberg  Automotive, Vesla, Corning, Budmat, Signify and many others. If you want to see our portfolio – go to the implementations.

Need vision system or packing robot? Contact us: office@alnea.pl

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Industry 4.0

OTHER SOLUTIONS:

9 August 2022
16 December 2020
3 November 2020
21 April 2020

WIĘCEJ

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 lines – design and modernization

Pozostałe wpisy:

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

WIĘCEJ

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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Alnea and Industry 4.0

Pozostałe wpisy:

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

WIĘCEJ

Since 2010, we have been creating a new reality by promoting Industry 4.0 in our region, in Poland, in Europe. We work with local companies, we implement production lines in Silesia and the Czech Republic. We have business partners in Hungary, Germany, the Netherlands and Italy. We started timidly, but we did quite well. We went through a few crises, a pandemic wiser for some experiences. We decided to summarize the first decade of Alnea.

Production 4.0

Modern production 4.0 is machines, robots and innovations. We have designed really large production lines, we managed to implement EOL testers, assembly lines and 3 unique customized production machines. We have 57 industrial robots, including cobots and AGV mobile robots.

 

Planing 4.0

Automation and robotization cannot exist without a good plan. Planning 4.0 is our domain. We have created 16 advanced visualizations of factories, machines and processes that can be viewed on Google VR. Thanks to this, we avoid costly errors during implementation, and the customer can see the entire concept in 3D instead of 2D.

Conference 4.0

Workshops 4.0 and conference 4.0 is also our domain. At the end of 2019, we got involved in the project proposed by the Platform of Future Industry. We trained over 60 top managers from all over Poland – we were visited by representatives of local companies, great plants on the food market, from the furniture and automotive industries.

Our knowledge of Automation and Robotization of the AiR Industry is another dimension of cooperation with local companies. We invite managers and directors of production companies to meet the best specialists in Industry 4.0. The third edition of AiR is coming soon!

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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Find the optimal solution – production test

Pozostałe wpisy:

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

WIĘCEJ

Modernizing the production line is sometimes a big challenge. A good process analysis performed in front of an experienced integrator allows you to identify areas of change in the production process or the product itself (if possible). How to find the optimal technological solution? – you need to test several different possibilities. Here are some of our experience as an  integrator  in a lighting company:

 

Production tests

Robotic position in the assembly line. The robot took the glass and placed the lamp in the housing, and then screwed the corners withagiven accuracy.

When we did the production tests for the installation of the lamps, we had a serious problem with the spacer, which was supposed to protect the fast during transport. The robot sometimes took the glass at the same time as the paper spacer, which created additional difficulties and simply took time. We did production tests and we were still not happy with the tacktime. We took a closer look at the spacer and found that it was completely unnecessary. Fast, they were extremely scratch-resistant. So we reduced spending – for the supplier, adding paper cardboard was also problematic and we accelerated the production process.

Positioning

The robot takes the LED plate and places it in the lamp holder.

We had a big problem with the positioning of the plate – there was no element in the housing to which the robot could position the plate so that it did not move. After analyzing the design of the housing, we proposed to change the casting so that the outline of the place for the plate is consistent with its circumference. Since the customer was able to redesign the housing, we gained on the accuracy of the insert arrangement, but also reduced the installation time.

Excessive tool wear

We have designed a tool specifically for the customer to screw screws into the housing. However, after implementation, it turned out that it wears out faster than weanticipated. It turned out that the product going to the paint shop had nosecuredplaces  for screws. The paint-drenched thread made it difficult to screw, destroy the tool and slow down the process. Simple solution – securing screw seats gave us savings  and faster lead times..

Production testers

Why invest in production testers? According to the OEE principle, it is better to produce less and better than more with defects. Production testers allow us to reject defective products so that they do not take up space, time and components for products made correctly. This is also important because of the level of energy consumption, the waste of which costs more and more. One such danger zone is the painter’s. Incorrect painting of an element makes it sometimes impossible to correct it anymore.  Testing the elements coming in and out of the painting shop – e.g. the Horus vision system –  allows for significant savings. The higher the Overall Equipment Effectiveness (OEE) rate, the better the production rate. Lepiej is to produce feweer elements, but of higher quality than more with high recoil.

Online consultation

A pandemic does not save manufacturing companies. So we offered our business partners a new solution. During the maintenance period of the machine [closed plants due to COVID],owe have put ina series of online consultations along with streaming the image from the production. We were able to optimize the process and changed the program on the machine.

After the implementation of the machine and after the warranty stage, the customer often introduces a new product type and changes need to be made – this sometimes applies to a very large number of machines. A safe option is to run tests on one device and then make changes and scale the solution to the next machine.

We adjust cooperation model at the project stage to ensure investor safety. Thus, the largest tranche of payments is accepted once the entire technical project has beenestablished. We treat customers as partners so we use flexible business models.

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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Industry 4.0 – support for companies

Pozostałe wpisy:

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

WIĘCEJ

The idea of Industry 4.0 is first of all a digitalization of  business and production processes. Collecting data and creating layers of information processing is now not only a vision, but a real need for Polish enterprises. Because Industry 4.0 is not just sensors,  IOlink, RFID or controllers, but above all system integration. Fortunately, at  Alnea we have gathered the necessary competences to support companies.

 

Cooperation is important

Consulting, auditing and implementing new technologies across a wide spectrum for different industrial companies is a big challenge. As a member of the Metal Processing Cluster, we often share knowledge and experience with our partners. We have established cooperation with the Foundation Industry of Future – this valuable initiative is precisely due to the assumption that cooperation is important. Also, our Conference of  Automation and Robotics of Industry is an action for the development of Polish North-East Region.

Training for managers

The fear that machines will replace humans has existed ever since mass production measures were introduced. However, a person will always be needed, it is important that he is in the right position. The competences of managers and engineers need to be further developed. That’s why we have a special training program for executives. The training program includes the presentation of industrial robots, cobots, mobile robots, management systems, new business models and specific implementations and innovation applications.

Our products

Creating our products such as Zeus Soledring  Set (robotic soldering) and Horus  Vision  System (robot positioning in space) we adapted them to the broader BIG DATA or IIoT  (Industrial  Internet of Things).  We can collect and process production data so that flexible small-series production is cost-effective, faster and user-friendly.

Why Industry 4.0?

Finally, the question we could start with. Why Industry 4.0? Industry 4.0 is an idea, not a finished product. Digitalisation, collaboration and are  essential. But we also need to produce these new technologies ourselves, otherwise we will only become consumers of products and services from abroad.

 

How to implement Industry 4.0?

Wondering where to start implementing new technologies or looking for new business models – please contact us!

We will come to you and offer you a good solution. We can also meet online to learn about your needs. We are flexible and we will tailor the best way to cooperate with your company.

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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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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