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Tag Archives: robot


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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Professions of future

Economic and social change has taken place extremely quickly over the last twenty years. The dynamic growth of available innovations and new technologies is noticeable in all areas of life, but above all in industry. Progressive automation and robotics shift production workers from simple actions to more advanced ones, and the concept of the profession of the future is slowly developed. However, for many years entrepreneurs have been struggling to recruit the right employees. This is because the education system is not flexible enough.

Difficult situation of employers

Many companies have launched their own employee training programmes. Some companies work with technical and industry schools to give young people the opportunity to practice, even those paid for in target jobs, with the promise of employment. A similar program was started by the Metalworking Cluster, of which Alnea is an active member. The cooperation of many companies with schools, the funding of laboratories and the purchase of new equipment or training of subject teachers turned out to be a great initiative, which was very successful in East Poland.

 

Activities of the Ministry of Education

The problems with educating young people have not been noticed by the government. The activities of the Ministry of Education are aimed at diagnosing demand and every year are published the most important professions of the future by specific provinces. Legislation already passed allows secondary school principals to create new class profiles. The combination of educational opportunities with the ministry’s forecast is already delivering concrete results. In particular, robot and automation distributors are happy to cooperate with technical universities and industry schools by retrofitting training stations. This is so important that young people learn from new technologies, not on machines remembering the late Polish People’s Republic.

Professions of the future

Listed in the notice of the Minister of National Education, the professions of the future are: automatic, electromechanics, electronics,  electrician, mechanic-fitter of machines and equipment, mechatronics, machine tool operator, automation techniques, road construction techniques, electronics techniques, electrician techniques, energy techniques, mechanical technician, mechatronics technician, programmer technician, welding techniques, robotics technician,  constructor/designer.

Interestingly, many of these professions are intended for people who would like to start working after school. The increasing digitisation and simplification of processes allows you to work in the profession without having to finish your studies.

 

Laboratory Program. My Profile

At Alnea, we know how important it is to educate children and young people. Laboratory project started by The President of Alnea Krzysztof Kamiński. My profile  is currently being implemented together with the Marshal’s Office and the Board of Education. With this initiative, students can visit different companies and talk to different employees about the opportunities of their professions.

Education at the conference

We also discuss the topic of education at the Conference on Automation and Robotization of Industry. In 2020, despite the sanitary restrictions associated with the epidemic, the debate was held with the President of the Metalworking Cluster from Bialystok – Sebastian Rynkiewicz, Director of the Electronic and Telecommunication Schools in Olsztyn – Grzegorz Górski, Artur Zawadzki – Operational Director of Promotech from Bialystok, Małgorzata Hochleitner Director of the Faculty of Education, Education and Care from the Warmia-Mazury Education Board and President of the Alnea Group – Krzysztof Kamiński.

If you would like to receive a new or refresh the old offer for a difficult time of crisis
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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!

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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Find the optimal solution – production test

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

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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