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Industrial Robotics Case Studies

September 2019

Automate for Accident Reduction

POSTED: 09/04/2019

Could you afford to lose 31.2 million working days? According to The Labor Force Survey, this figure illustrates the volume of unplanned worker absence due to non-fatal workplace injuries. In fact, the number of non-fatal workplace injuries in reached 609,000 in 2017 — with cuts and lacerations among the most

August 2019

Solenoid Mechanical and Electrical Testing with SMAC

POSTED: 08/29/2019

While we all dream and work countless hours to land that giant  OEM, developing a technical solution, solving their problem(s), and winning the business, but staying close to custom machine integrators is a great way to get projects, keep the orders coming in and have another pair of feet on

POWERTRAIN – CASE STUDY

POSTED: 08/23/2019

PLATE PACKING LINE SYSTEM FOR DUAL CLUTCHES In the case of the clutch packs for a dual clutch, the deviations of the friction and clutch plates are optimally equalized. Precision is key here: The thicknesses of the plates are measured and classified with a high

POWERTRAIN – CASE STUDY

POSTED: 08/23/2019

REAR AXLE TRANSFER TRANSMISSION WITH RIGID AXLES The assembly line system includes all measuring and assembly processes for a rear axle transmission, plus additional modules for assembling the axle tubes, side shafts and wheel bearings with the brake modules. Due to the size and weight

When to Automate

POSTED: 08/08/2019

CLIENT One of the largest bagel bakeries in the US has grown from a single storefront location into a large wholesale bagel maker producing more than a million bagels each day across multiple production facilities. Motivo was asked to review the client’s production operations and search for opportunities to improve efficiency

Robotic Lab Assistant

POSTED: 08/08/2019

CLIENT Breakwater Research is an energy research firm in San Jose, California. With the fast-paced progression of modern society, energy research and development of more efficient energy storage is becoming increasingly important. Breakwater Research is primarily focused on cutting edge research in the field of advanced hydrogen storage. CHALLENGE Hydrogen storage is a

Rethinking Commercial Fruit Harvesting

POSTED: 08/08/2019

CLIENT Motivo’s client is a family-owned farm known for their high-quality, unique, and flavorful fruit. This client values innovative farming techniques and sustainable practices. CHALLENGE Picking fruit has typically been something that is done by hand, mainly due to how easily fruit can be damaged and the variability in grown products. Harvesting includes

Processing Produce With Artificial Intelligence

POSTED: 08/08/2019

CLIENT Motivo’s client is a wholesale distributor of processed fruit and vegetables located in the USA. Alignment is critical when slicing or coring the client’s products; an incorrect slice can lead to tossing an entire fruit away and greatly influence the viability of the business. This was a task that only

Meat Processing Automation

POSTED: 08/08/2019

CLIENT A major vertically-integrated poultry producer on the West Coast, Motivo’s client suffers from limitations to the growth of its business due to rising costs, high employee turnover, and the labor-intensive type of work required. CHALLENGE Poultry is primarily processed with manual labor due to the poultry’s organic and varying shape. These manual

Automated Broccoli Transplanter

POSTED: 08/08/2019

CLIENT Greenheart Farms is one of California's leading vegetable producers and transplant services providers. As labor resources become scarcer and costs increase, Greenheart has been dedicated to developing technical solutions to remain an industry leader. Greenheart and Motivo teamed up to develop an automated transplanter. CHALLENGE Nature is messy! Not only did the

Advancing Sweet Potato Transplanting Technology

POSTED: 08/08/2019

CLIENT Black Gold Farms is a nationwide, family-owned potato grower with an appetite for innovation.  With challenges like increasing labor scarecity and rising costs, Black Gold Farms is taking the future of their business into their own hands. REQUIREMENTS An automated sweet potato transplanter needs to make business sense: improve transplanting speed and

July 2019

Autonomous Robotics: Intel® RealSense™ Technology and BrainOS

POSTED: 07/31/2019

An article written by Intel RealSense Technology. Published on February 8, 2019. It’s predicted that by 2065, Japan’s working population could shrink by as much as 40 percent, to around 45.3 million workers. This has led to a tight labor market – especially in blue collar jobs – with a variety of

Automation in one batch

POSTED: 07/31/2019

Robot-assisted automation in the manufacture of small quantities: This challenge has been accomplished by Darne Sport Composites S.L. in Spain. The company manufactures high-value CFRP components for motor racing and employs an ultra-flexible Stäubli six-axis robot for the milling and drilling of molds, models and CFRP components. Every automotive plant and

A world first: Robots used in the reclamation of hip bones for implants

POSTED: 07/31/2019

Belgian start-up Texere Biotech has recently begun production at a fully automated plant, the first of its kind in the world. The company takes femoral heads (i.e. the top end of the human thigh bone) and processes them into cuboid implants or “allografts”. Six Stericlean robots supplied by Stäubli handle

A world first: Robots used in the reclamation of hip bones for implants

POSTED: 07/31/2019

Belgian start-up Texere Biotech has recently begun production at a fully automated plant, the first of its kind in the world. The company takes femoral heads (i.e. the top end of the human thigh bone) and processes them into cuboid implants or “allografts”. Six Stericlean robots supplied by Stäubli handle

HE (Humid Environment) robot excel where others fail

POSTED: 07/31/2019

100 percent humidity, 43°C ambient temperature and a pH of 9: in such conditions, the deployment of robots poses real challenges. These are the very parameters under which Stäubli TX200 HE robots are delivering reliable service on the parts cleaning line at the Nissan Dongfeng engine plant in China. Nissan sold

How RIVA meets the requirements of the future

POSTED: 07/31/2019

The aseptic preparation of drugs such as infusion solutions is one of the more complex tasks in pharmaceutical dispensing. In addition to creating the right conditions for production, the right technology for automation of the process has to be identified and implemented. ARxIUM is a multinational company that offers clinics

The Mega Cell

POSTED: 07/31/2019

The assembly of pressure relief valves for the ventilation of car engine crankcases is a detailed process that presents multiple challenges: an annual output of three million units, tolerances in the hundredth of a millimeter range and strict quality assurance procedures call for a superior automation solution. Working on behalf

Machine automation taken to the next level

POSTED: 07/31/2019

Around 20 million cutter blades for hair clippers and beard trimmers leave the Philips plant at Klagenfurt every year. In order to make the complex grinding process as efficient as possible, the company has opted for a pioneering automation concept, where the loading of the machine and the delivery of

Robot braves ultra-harsh conditions

POSTED: 07/30/2019

To maintain competitive production costs in traditionally high-wage countries such as Austria while guaranteeing customers goods of consistently high quality, precision parts manufacturer Redtenbacher has opted for an exceptionally high degree of automation. The relevant machinery and equipment are mostly developed and built in-house. Their rotary indexing cell was designed

Staubli Robotics assisting business with Cleanroom molding challenges

POSTED: 07/30/2019

Stäubli Robotics assisting businesses with Cleanroom molding challenges PTG Silicones invested a full year designing and constructing its state-of-the-art manufacturing facility which features a class 100,000 Cleanroom.  As a supplier to both the food packaging and healthcare industries one of the company’s biggest challenges was to create an environment that utilizes

Custom-Engineered EOAT and Degating System

POSTED: 07/22/2019

How Piab helped an automotive parts leader automate a complicated degating process and increase productivity with a specially designed end-of-arm tooling (EOAT) system. The Client Delphi is one of the world’s leading suppliers of electronics, parts, and technologies for the consumer and commercial segments of the automotive industry.

Case Study: Automating End-of-Line Processes in a Traditional German Brewery

POSTED: 07/10/2019

Westheimer Brewery, founded in 1862, is a private brewery rooted in more than 150 years of tradition. From their factory in the Sauerland region of Germany, they produce regional beer specialties and prepare them for distribution both regionally and internationally. In order to remain competitive in an increasingly diversified market,

Case Study: A New Solution for Bag Palletizing Using a Kawasaki Robot

POSTED: 07/10/2019

In most factories, end-of-line processes are sought-after candidates for automation. The combination of ergonomically challenging work and simple, repetitive movements make end-of-line tasks tedious and, oftentimes, easy to program. However, in the landscaping industry, palletizing bags of soil and mulch has always been a relatively difficult process to automate. Dropping lightweight,

Adjustable Width Timing Belt Coneyor

POSTED: 07/10/2019

Challenge To provide a conveyor that would accommodate 49 different size bolts while maintaining a common datum. And allow for seamless integration within the robot work cell, all while being operator safe. Solution An adjustable width timing belt conveyor, with one set of belt fixtures designed to accommodate all bolt types while providing

True Conveyor Belt Tracking

POSTED: 07/10/2019

Recently a customer approached mk North America, Inc. with a unique conveying application which required transporting carriers containing catalytic converters. The carriers were slightly over 3-inches in diameter, but all told would weigh in at 225 lbs. The carriers were being fed onto the mk conveyor from an existing recirculating

PDSI Case Study: Using Simulation to Create a Winning Proposal

POSTED: 07/02/2019

A Major Project Opportunity with Tough Requirements Located in Dayton, Ohio, Production Design Services, Inc.; or PDSI, has been providing cost-effective solutions for complex manufacturing problems for more than 60 years. As a supplier and integrator of fixed and flexible turn-key automation solutions, PDSI has designed hundreds of cells for a wide variety

June 2019

Virtual Manufacturing Project Case Study

POSTED: 06/19/2019

Virtual Manufacturing, a supplier of lean-based production development services, and value-added reseller of Visual Components solutions; understands the power of simulation in production. In this case study, we’ll review a project they recently completed to drive sales of their lean manufacturing products, using the Visual Components Experience app. About Virtual Manufacturing “Our goal is

Savushkin Project Case Study

POSTED: 06/19/2019

Many manufacturers are struggling to keep their production efficient while at the same time responsive to changing market needs. Producers in the dairy industry are facing the same challenges. Leading dairy producers like JSC Savushkin Product are turning to digital manufacturing and Industry 4.0 technologies to help them reduce time to market

O&O Technology & SMB Technics Project Case Study

POSTED: 06/19/2019

SMB Technics, a leading Turkish producer of metal processing solutions for the manufacturing industry, was recently competing for a project that required them to propose and present a complete manufacturing solution. As part of the bidding process, SMB Technics had to demonstrate that they could deliver a solution that met

Midea Case Study

POSTED: 06/19/2019

In this case study, we’ll show you how Midea, the world’s largest producer of major appliances, used Visual Components to increase the capacity and flexibility of a high-end washing machine assembly line, while reducing costs by 15%. The World’s Largest Producer of Major Appliances Established in 1968 and headquartered in Southern

May 2019

Case Study: Consistent Spraying in an Unfriendly Environment Using Kawasaki Robot

POSTED: 05/22/2019

In the eyes of some manufacturers, installing an industrial robot can seem intimidating. Misconceptions of having to rebuild everything from the ground up and having to adopt a completely new process can make automation seem like a bigger endeavor than it truly is. In reality, there are many ways to

Case Study: Kawasaki Robotic Tube Bending Increases Throughput and Eliminates Safety Risks

POSTED: 05/22/2019

Robotic machine tending can offer a wide range of benefits, whether it is ergonomic relief, increased throughput, or a more streamlined and efficient process overall.  For Kawasaki Motors Manufacturing Corp., USA (KMM), automation helped them in all of these areas. Five years ago, KMM installed their first tube bending cell using

Case Study: Flexible and Consistent Arc Welding Using Kawasaki R series Robots

POSTED: 05/22/2019

As experienced arc welders become an increasingly scarce resource and mass production amplifies the need for consistent product quality, many companies are at a loss.  They need to weld their parts, but it’s difficult to find skilled welders who can produce high quality products, let alone maintain that standard of

Case Study: Creating a Customized Kawasaki Robotic Solution for Produce Palletizing

POSTED: 05/22/2019

When ever-increasing production goals are met with high labor and shipping costs, robots can help manufacturers improve their bottom line.  In the case of Cecelia Farms, automating their palletizing operations with Kawasaki has helped the produce company increase throughput while avoiding labor costs. Caxton-Mark, a robotic integrator out of Leamington, Ontario,

Case Study: One-of-a-Kind Kawasaki Robot Cell for Vision-Guided Aerospace Part Assembly

POSTED: 05/22/2019

Unlike many of today’s manufacturing sectors, the aerospace industry tends to stray away from automation. While automated machinery is commonly found on the aerospace factory floor, robotic arms are a rare sight due to low production volumes and the delicate nature of creating such specialized parts. This aerospace part supplier teamed

Robot Cuts Costs, Increases Efficiency

POSTED: 05/20/2019

When asked how his Columbia/Okura robot is perfomring, Big J Milling Co. President John reese jokingly remarks, "it puts in a 24-hour day, it doesn't get sick, and it always shows up on time." Of course, robots will always have an edge over human employees when it comes to issues such

Case Study: Six-Station Machine Tending Using Kawasaki Robot

POSTED: 05/20/2019

Manufacturers use automation to take their operations to the next level.  Whether it is increasing throughput or decreasing labor costs, the integration of robotics gives enterprises of all sizes the opportunity to expand their business and eliminate pain points in their processes, which oftentimes has a ripple effect of unforeseen

Brain Corp Creates New BrainOS To Scale Robotics Across Industries

POSTED: 05/17/2019

This case study was written by Brain Corp in collaboration with NVIDIA for their product showcase. Published on May 17, 2019. Being a leader in software means working with the industry's best-in-class hardware providers. Brain Corp collaborated closely with the NVIDIA Jetson team during development of Whiz, a commercial autonomous vacuum

December 2018

Robotic palletizing solution from Honeywell Intelligrated adds staffing and production flexibility

POSTED: 12/06/2018

Robotic Palletizing Solution From Honeywell Intelligrated Adds Staffing and Production Flexibility, Avoids Worker Injuries, and Yields Floor Space Savings Please note: “Honeywell Intelligrated” within this case study refers to FKI Logistex. Intelligrated, which was purchased by Honeywell in 2016, acquired the North and South American operations of FKI Logistex in 2009. Dan

Universal Robots help Autodesk Push Construction Industry’s Boundaries for Human-Robot Collaboration

POSTED: 12/05/2018

At Autodesk’s Robotics Lab in San Francisco, CA, Universal Robots are used in research projects exploring new ways to automate the construction industry. The projects span human-robot interactions, machine learning, drawing and smart assembly systems. Crazy. That’s the response Heather Kerrick, Senior Research Engineer at Autodesk’s Robotics Lab, often encountered when

LEONI B-Flex Brings True Collaborative Cable Management to Cobot Models

POSTED: 12/04/2018

With an increase of collaborative robots in manufacturing environments, more and more cobots are working alongside humans. As these robots are automating tasks, they need to be equipped with the proper content and utilities, which in turn requires proper cable management.  As important as it is for the robots to

November 2018

The Growing Role of Electromechanical Actuators in Automotive Manufacturing

POSTED: 11/26/2018

Maintaining a competitive edge in the global marketplace requires manufacturers to continually search for new processes and technologies that increase production quantity, quality, and flexibility. Nowhere is this more apparent than in the automotive industry where shorter time-to-market cycles and ongoing cost containment are critical to enhancing shareholder value in

Maintenance free UR cobots operate continuously in harsh environment

POSTED: 11/13/2018

Aircraft Tooling, a Texas-based repair center for the aviation industry, was surprised to find that Universal Robots could withstand the high temperatures and harsh environment while performing metal powder and plasma spray processes. The UR “cobots” have now been in operation for three years without breakdown or service requirements. “It

October 2018

Retrofitting CNC machines with RG2 Dual Gripper

POSTED: 10/26/2018

The Copenhagen-based company has increased its productivity on their CNC machines by retrofitting them with RG2 Dual Grippers from OnRobot that significantly decrease cycle times and allows for production to continue after operators have left the workshop. COPENHAGEN – Many years ago, Sen. Everett Dirksen is reported to have said, “A

OnRobot collaborative grippers pack delicate herbs at Rosborg Greenhouse

POSTED: 10/26/2018

It takes great finesse to cultivate and deliver tasteful, fresh herbs. It requires intelligent automation to ensure that production is efficient, competitive, and creates a good work environment. That is why Denmark’s largest producer of herbs and mini plants, Rosborg Food Holding, chose to invest in sensitive, flexible robot grippers from On Robot to handle the plants. The use of herbs dates back to Babylon

IAS project case study: Automate a seed-testing lab

POSTED: 10/02/2018

IAS Inc., a Wisconsin-based systems integration company and Visual Components customer, recently told us about a unique project they completed for a Fortune 500 agricultural company — automating a seed-testing lab. “The customer had been using a crew of over 100 people, with each person individually performing the entire preparation portion

August 2018

Robots: Saving Your Jobs, Not Destroying Them

POSTED: 08/28/2018

You know the common fear: robots are coming to take your jobs. This fear of new technologies dates back hundreds of years about the inevitable changes that they bring. However, again and again it has proven that while some jobs are lost, they are ultimately replaced with new ones. Past technological

OCTOPUZ Programs Panasonic Welding Robot at Accumetal Manufacturing Inc.

POSTED: 08/14/2018

Just like there are a multitude of robot brands in the industrial robotics industry, there are also a multitude of options for programming. Manual programming, OEM specific software and third party offline programming software are some of the different approaches. OCTOPUZ Offline Programming and Simulation Software is a third-party software solution

Crown relies on FASTSUITE Edition 2 for offline programming of robotic welding cells

POSTED: 08/10/2018

Robot welding: More efficiency for programming and equipment fabrication The forklift manufacturer Crown relies heavily on robotic welding automation for production of their equipment in the Roding (Germany) facility. The results for increased productivity and weld quality are quite impressive and therefore the number of automated welding systems has continued

Removing Production Bottlenecks through Automation

POSTED: 08/07/2018

Tufting, one of the most sought-after and classic upholstery styles, is commonly incorporated into the design of furniture. How is this Victorian button-like look achieved? We got some insight from Fibreline, the largest independently owned

July 2018

OCTOPUZ: Preparing Students for the New Industry Standard

POSTED: 07/31/2018

Throughout a student’s education, the student is taken through a curriculum that shapes him/her in the best way possible for their career path. Only so much can be covered in the time allotted and it is often difficult for students to pursue their own interests within the field. It is

Stepping Into the Future With Old World Stone

POSTED: 07/25/2018

Burlington, ON - based Old World Stone, has been providing cut stone for over 30 years.  From humble beginnings, they have grown to become one of North America’s premier suppliers of dimensional cut sandstone, limestone, and marble.  At Old World Stone, they combine the traditional craft of cut stone in

Polywood, LLC

POSTED: 07/16/2018

BACKGROUND Poly-Wood, LLC is an innovative outdoor furniture company whose mission began in 1990 with two high school friends in an Indiana garage who posed the question, “what happens to all the milk jugs that get recycled?”. These friends, Doug Rassi and Mark Phillabaum, had a vision for creating game-changing, high-quality

Case Study: Masterbuilt And Encompass Solutions Managed Services

POSTED: 07/10/2018

Encompass Solutions recently sat down with Masterbuilt Director of Information Systems Cristina Robinson to discuss the company's utilization of Encompass solutions' Managed Services, manufacturing top-of-the-line cooking equipment, and the future of Masterbuilt. Here's what Cristina had to say about his company and where she hopes to growth enabled by the essential

Automotive Supplier Increases Uptime, Production Volumes with LEONI LSH 3 Dresspack

POSTED: 07/05/2018

A Tier 1 supplier to top global automakers had been using dresspacks on various production-line robots for more than a decade. After contending with frequent failures and downtime caused by cable management systems from various vendors, the company enlisted the expertise of LEONI Engineering Products & Services, Inc. (LEPS). The

June 2018

Smooth Integration with Complete Tool Systems

POSTED: 06/27/2018

Automation of nut and bolt welding is Lerocon’s speciality. Customers are primarily in the automotive industry. The product portfolio includes resistance welding and part feed using vision systems. Robot System Products supplies automatic tool changers, complete with cable

Swivel Increases Robot Flexibility

POSTED: 06/27/2018

In some cases, it is possible to add more flexibility to the robots and thereby extend their application possibilities. Using a swivel from Robot System Products, the injection moulding company Denk Kunststoff Technik, extended

Gluing Made Easy!

POSTED: 06/27/2018

When the German company FRIMO established a plant for gluing interior fittings for the car industry, the opportunity to fully utilize its robots' mobility was decisive. Equally significant was the capacity to automatically change tools with precision and

Tool Changers Enhance Flexibility at Scania Oskarshamn

POSTED: 06/26/2018

The efficient use of industrial robots requires tool changers, according to experience gained from Scania’s new bodywork facility in Oskarshamn, Sweden. When choosing supplier, quality and support are crucial factors. Scania’s facility in the Swedish coastal town

Metaphase Technologies President Kevin High Gives His Thoughts On ERP, Manufacturing, And Customized Machine Vision Technology

POSTED: 06/01/2018

Encompass Solutions recently sat down with Metaphase Technologies President Kevin High to discuss the company's current Epicor ERP implementation, manufacturing custom vision and lighting solutions, and the future of Metaphase. Here's what Kevin had to say about his company and where he'll be taking it with the advanced capabilities Encompass Solutions

May 2018

Aluminum Arc Welding

POSTED: 05/14/2018

Project Challenges Provide a flexible robotic welding system to automate welding of new designs of fence posts and gates. Provide a complete turnkey robotic welding system that is able to accommodate xx variations of parts with minimal tooling change over. Large awkward parts consist of .250” aluminum welded to .060” aluminum tube

April 2018

Doxsteel Fasteners Finds Success In ERP Implementation, Multilingual Training, And International Compliance Satisfaction With Encompass Solutions, Inc.

POSTED: 04/19/2018

Doxsteel Fasteners recently achieved a significant milestone in bringing its Mexico-based operations up to speed with a complete implementation of Epicor version 10 software and user training for their Mexico-based teams. Skilled consulting, implementation, and training services provided by Encompass Solutions, Inc. ensured the project was a success. The Project Up to the point

January 2018

Innovative Material Storage & Handling Solutions Improves Operating Efficiency

POSTED: 01/31/2018

Glory Global Solutions was facing a warehouse storage and handling challenge with limited space, low clear heights and insufficient capacity. The company utilized a third-party logistics provider for additional support, but recognized the opportunity for an in-house solution that would increase its customer equipment assembly, configuration, storage and shipping efficiency. Glory

Velox Machine Guarding Protects 3-Dimensional AS/RS Solution

POSTED: 01/31/2018

Situation: Advance Storage Products responded to a new customer request to design and implement an automated storage and retrieval system (AS/RS) that would allow the company to efficiently transition from a third-party logistics provider to an in-house operation in its production facility. The solution needed to utilize the company’s existing

December 2017

The Dixie Group DC Operational In 10 Weeks

POSTED: 12/21/2017

Husky Rack & Wire and Commercial Storage Systems worked as a team in the design and installation of a critical material storage and handling solution under a tight timeline for The Dixie Group Operations in Chattanooga, TN. The Dixie Group needed to find a storage facility that would accommodate over 3.3

Reduce Injuries and Increase Productivity with the FT 300 Force Torque Sensor

POSTED: 12/13/2017

Saint-Gobain’s plant in Sully-sur-Loire, France, focuses on glass production for the armoured and aeronautical industries, and the civil market. In their shift towards industry 4.0, management has deployed collaborative robot cells to free employees from tedious, repetitive tasks. Robotiq’s FT 300 Force Torque Sensor has proven essential to automate the

OCTOPUZ Case Study: The Benefits of Full Automation

POSTED: 12/12/2017

For over 30 years Focus Auto Design Inc, based in Calgary AB, has been manufacturing OEM appearance accessories. Recently, with a change in their manufacturing processes they have successfully launched an innovative new product known as the Tough FormFit Guard, a rouged hood protector manufactured from acrylic capped ABS. This new

November 2017

Velox Machine Guarding Protects Omni-Channel Fulfillment Center

POSTED: 11/14/2017

Invata Intralogistics, experts in advanced automation systems, selected Velox Machine Guarding to protect its new 465,000 square foot omni-channel fulfillment center. Invata designed and built the facility for Destination Maternity Corporation, the world’s largest designer and retailer of maternity apparel. The facility and controlled warehouse automation system incorporated a wide array

October 2017

IAS Case Study

POSTED: 10/06/2017

IAS Inc. is a full systems integrator that develops automation systems to bring cutting edge technology to life. They started with a wide customer base in industries such as food & beverage, automotive, and general manufacturing, giving them a diverse wealth of knowledge and a holistic engineering approach under one roof.

September 2017

Doubled Production on Limited Floor Space

POSTED: 09/28/2017

A year ago, German audio equipment leader beyerdynamic aimed to increase factory floor productivity by 50% on a 4-year plan. This had to be done in the same production space, without compromising the brand’s highest quality standards. A Vision System That Solves Every Manufacturer’s Problem Collaborative robots rapidly became the number

Wrist Camera Increases Daily Production to Deliver Big Orders in Tight Delays

POSTED: 09/28/2017

Mississippi’s WALT Machine Inc. specializes in high-precision optical work for scientific camera assemblies. Each spring WALT Machine must meet a massive challenge: Deliver around 6000 camera housings in 2 months’ time, with only one CNC machine. A First Simple Vision System for Collaborative Robots Being able to deliver this massive order

August 2017

Control Panels USA and OCTOPUZ: A Winning Combination

POSTED: 08/23/2017

Control Panels USA is a UL508A, UL698A, & UL698B manufacturer of Control Panels and Relay Rack assemblies for clients in a wide range of industries. They have been providing reliable,

KUKA Case Study

POSTED: 08/22/2017

A highly developed ready-made solution When dealing with highly sophisticated production lines and multi-robot work cell installations one of the best ways to test and verify decisions is to simulate in a 3D environment and see these operations as realistically as possible in real-time. KUKA chose the Visual Components simulation and

Fastems Case Study

POSTED: 08/22/2017

How has Fastems benefited from collaborating with Visual Components? Fastems, an independent robot integrator with over 20 years of experience in the machining industry, is a major player in the field of robot integration. The company employs 500 people worldwide and since its founding in 1990, Fastems has delivered over

Bell Helicopter Case Study - Setting the Pace for the Vertical Lift Industry

POSTED: 08/21/2017

Robot simulation in the aviation industry Bell Helicopter is a Texas-based manufacturer of vertical lift aircraft. Bell has become the industry leader since its founding in 1935 and was also the first company in the world to obtain certification for a commercial helicopter. Bell Helicopter representatives were able to see firsthand

Kaufman Case Study

POSTED: 08/21/2017

Kaufman Engineered Systems has been at the forefront of complete line automation for over 70 years. Hundreds of successful companies have chosen them for their single-source convenience, responsive service, and unmatched machine performance. Kaufman has become an international leader in the fields of robotic palletization, stretch wrap systems, conveyor systems, and

July 2017

Collaborative Robots in the Classroom Deliver Hands-on Learning

POSTED: 07/20/2017

RAMTEC Career center in Ohio is home to the largest, most comprehensive robotics education center in the U.S. In order to increase the number of skilled manufacturing employees to meet future market needs, the school is now training students ranging from middle school to industry professionals with collaborative robots from

Universal Robots Saves 9 Hours of Production Time at Glidewell Laboratories

POSTED: 07/20/2017

It usually takes five days from when a dentist sends an impression of a patient’s teeth to the lab, until the finished crown returns.  A process, that Glidewell Dental Laboratories wanted to optimize.   David Leeson, engineering manager at Glidewell, had his eyes on Universal Robots’ collaborative robot arms as he

How Dynamic Group Quadrupled Production Capacity with Collaborative Robots

POSTED: 07/20/2017

Dynamic Group had difficulty staffing their injection molding production and wanted to better utilize their existing labor force. Three collaborative robot arms from Universal Robots have now taken over several repetitive tasks resulting in improved product consistency and production capacity increases of up to 400%. Dynamic Group, a Minnesota based contract

A Robot Cell for Sound Deadener and Blackout Spray

POSTED: 07/07/2017

Problem: One of our long-term customers in the automotive industry reached out to us for advice on improving a step in their manufacturing line for a new model of vehicle.  The existing process used employees to manually spray sound deadener and blackout material under vehicles.  The two main reasons to automate

Piston Ringer Assembly: Rewriting the Code

POSTED: 07/07/2017

Problem: One of Patti Engineering’s customers in the heavy equipment manufacturing industry came to us with a project to upgrade the controls program for a piston ringer assembly. The fully-automated subsystem contains a 6-axis robot and 6 rotary tables which install 3 piston rings on each piston set. The assembly process

How Dimic Steel Tech Cut Their Programming Time In Half

POSTED: 07/06/2017

Dimic Steel Tech, a metal fabrication and machining service provider in Upland, California uses OCTOPUZ to program their robot, a KUKA KR 16 for MIG welding, from start to finish. Every part they have is programmed in OCTOPUZ so that it is easily placed on

June 2017

Building today's manufacturing startups

POSTED: 06/07/2017

Since the 80’s, American eyewear manufacturers were all bought by foreign interests, stopping the domestic production in the process. Since then, most american eyewear brands sell products that are made overseas. Two years ago, an architect, Brian Vallario and his friend Gerard Masci, a finance worker, decided that the time

May 2017

GE Achieves Lean Manufacturing in Milwaukee Facility with OTTO

POSTED: 05/24/2017

THE TASK: DELIVERING MEDICAL EQUIPMENT  GE Healthcare’s 280,000 square foot facility in Milwaukee is a mega center for medical equipment repairs. Multiple U.S.-based repair operations have consolidated into this site, and it now functions as a showcase for the use of advanced technology to improve process in material handling. The facility

Severt Chooses Delfoi Arc for Flexible and Easy Programming and Manufacturing

POSTED: 05/15/2017

Severt's Target - More Flexibility and Efficiency, Shorter Programming Time and Availability of Robot Cells To meet customer demands flexibility is crucial. The trend in manufacturing of steel components is going towards small and medium sized lots and shorter batch sizes. Berthold Elkemann is an expert in programming welding robots, and he

March 2017

JST Goes to Great Lengths to Advance Semiconductor Manufacturing with Rexroth Automation

POSTED: 03/23/2017

Challenge Create a 138-foot-long wet bench silicon cleaning station utilizing multiple Cartesian robots driven by a combination of linear motion and control technologies Rexroth Solution CKR belt-driven linear modules CKK ball screw linear modules MKR belt-driven linear modules IndraDyn MSK synchronous servo motors IndraDrive C digital intelligent servo drives Rexroth EasyHandling System Results Effective use of overhead Cartesian robots Precision,

Robotics Makes the Right Move for Medifast

POSTED: 03/22/2017

Delta robot adds flexible automation, improves transfer between poucher and cartoner Challenge: Improve product transfer between Medifast's pouching and cartoning machine KHS Bartelt and Rexroth Solution: Three-axis delta picker robot controlled by Rexroth’s IndraMotion MLC motion logic control platform IndraControl L65 controller with Sercos ring IndraDrive Mi cabinet-free integrated servo motor/drives IndraDrive M digital intelligent servo drives IndraDyn

5 RTOS Performance Compared on EtherCAT Master – IntervalZero’s RTX/RTX64 Stands Out

POSTED: 03/15/2017

The KINGSTAR Soft Motion platform supports multiple industry-leading EtherCAT Masters to guarantee that devices from different manufacturers can work together seamlessly. The centralized controller architecture provided by an EtherCAT Master ensures all of the benefits of EtherCAT technology, like real-time operations, short cycle times, and maximum performance for minimal expense. One

February 2017

Electromechanical Actuators in the Automotive Industry

POSTED: 02/03/2017

Linear actuation is a core technology for factory automation. Along with fluid power, (hydraulic and pneumatic), electromechanical actuators have become increasingly important in all common industries like packaging, food, energy, process control, construction, and the automotive industry. Manufacturing lines, using linear actuators, are an integral component of today’s industry. However,

Electric Actuators Enable Precise and Highly Dynamic Metering

POSTED: 02/03/2017

Accurate and repeatable dispensing of adhesives and sealants is critical to ensuring design integrity and performance of finished assemblies in industries such as automotive manufacturing, aerospace, renewable energy, electrical and electronics, and the production of white goods. Mixing and dosing of media directly at the application site significantly increases dosing

December 2016

Universal Robots Racks Up the Benefits at Etalex

POSTED: 12/12/2016

Installing a Universal Robot to pick metal parts out of a press brake solved several automation headaches at Etalex; a Canadian manufacturer of shelving systems that had no room for safety guarding in front of the press and needed a flexible user-friendly robot that could safely handle the pick and

Mobile Robot Colleagues on Wheels Increase Productivity and Worker Safety at Scott Fetzer Electrical Group

POSTED: 12/12/2016

A mobile fleet of Universal Robots will now receive daily work orders to solve ever-changing tasks with high mix - low volume electronics manufacturer Scott Fetzer Electrical Group (SFEG) in Tennessee. The collaborative robots have optimized production by 20 percent, taking over monotonous and potentially hazardous tasks from employees now

Robot Colleagues Boost the Bottom Line

POSTED: 12/12/2016

For the Danish company Stantræk, automation means growth. The company that processes sheet metal and coils is now able to expand production without significant increases in payroll. From 2008-2013, revenue nearly doubled from $4M to $7M while the number of employees increased from 21 to 28 only. Much of the

Vision-Guided Collaborative Robots Deliver Fast Return On Investment in Production of Firehose Valves

POSTED: 12/12/2016

Task Force Tips, a manufacturer of firefighting equipment, wanted to promote and maximize their personnel tending machining cells into more complex tasks while keeping spindle time up and product quality consistent. The Indiana-based manufacturer has now installed four collaborative Universal Robots delivering savings resulting in a return on their investment

November 2016

Shifting into the Future with OCTOPUZ Robotic Software

POSTED: 11/18/2016

In an ever-competitive and increasingly globalized world, the automotive industry is constantly striving for innovation. This creativity is often applied to vehicle interiors, where their design has remained an important factor for today’s discerning customer, especially in the luxury market. In Germany, international part-manufacturer Oechsler recently forged a partnership with MBFZ toolcraft GmbH where

October 2016

Quanta Storage Case Study

POSTED: 10/03/2016

Background Quanta Storage, a subsidiary of Quanta Computer, is one of the major suppliers of storage products to leading computer manufacturers around the world. Relentlessly focused on innovation, Quanta aimed to evolve its products into the cloud and beyond, and also revolutionize its manufacturing processes for greater efficiency and control. Quanta

September 2016

Machine Automation Best Practices for Surface Mount Technology (SMT)

POSTED: 09/28/2016

How KINGSTAR Transformed Motion Control At 4 Leading SMT Corporations Summary Around the world, KINGSTAR products including the IntervalZero real-time operating system (RTOS) are used in dozens of different models of surface mount technology machines (SMT), which are produced by many different customers with  prestigious brands. This success story shares best

Chime Ball Tech - Performance & Agility Through Decentralized Software Motion Control

POSTED: 09/25/2016

How Chime Ball Technology (CBT) Replaced Traditional Motion Control for Greater Performance and Value The Organization: A Leader in Automatic Exposing Machine and Circuit Board Production Chime Ball Technology Co., Ltd. (CBT) produces CCD automatic alignment exposing machines for PCB printed circuit boards, and FPC soft printed circuit boards built for

June 2016

Revolutionizing the Dairy Industry

POSTED: 06/23/2016

The Kroger Company (Kroger)(NYSE:KR) is one of the world’s largest grocery retailers with fiscal 2014 sales of $108.5 billion. Kroger runs 37 manufacturing plants that produce about 40 percent of the corporate brand units sold in its stores throughout the United States. Challenges TO DELIVER EXCEPTIONAL QUALITY and freshness to its

Utilizing Warehouse Automation

POSTED: 06/22/2016

L’Oréal U.S.A. (L’Oréal) is the world’s largest health and beauty care company with fiscal 2015 sales of $28.39 million. Founded in 1909, L’Oréal is based in Clichy, France with headquarters in New York City, Berkeley Heights, NJ and Melbourne, Australia. L’Oréal is present in 130 countries with 43 factories and

May 2016

IPSUMM’s New Flexible, Scalable IRIS Production Cells Promise to Revolutionize Conventional Manufacturing Processes — with a Little Help from Mitsubishi Electric

POSTED: 05/17/2016

Solution RV2FBD1S15 6-Axis Robot L02CPU-P Programmable Logic Controller IPSUMM Product Benefits Quick switching among diverse manufacturing tasks Easy to reconfigure manufacturing capacity Scalability reduces capital investment demands Mitsubishi Electric Value-added Advantages Robust programming support Timely product availability Responsive service BACKGROUND Newly expanding to a 18,000 sq. ft. facility in the scenic,

March 2016

Five Robots Travel Around the World – Centralized unitizing robots prove reliable and flexible

POSTED: 03/17/2016

Motion Controls Robotics, Inc (MCRI) helps a large pulp and paper company relocate and expand their current robotic unitizing system. FREMONT, OH  – Seven years ago MCRI designed and integrated a robotic unitizer using five, FANUC M410 robots for centralized unitizing of caseloads from production at a large

How to Properly Seal Housings with RTV Silicone

POSTED: 03/01/2016

Problem A manufacturer of hybrid power electronics needed to assemble and seal control module housings with high efficiency and 100% confidence. Solution Flexible Automation, Inc. (FAI) manufactures robotic systems that assemble and test automotive, consumer, and medical devices. 30 years of experience led to a system that dispenses RTV silicone and

Automated Clutch Assembly Pack Machine

POSTED: 03/01/2016

Problem A company recently contacted Flexible Automation Inc. with a need to assemble clutch packs and be able to run verification tests post assembly to ensure quality. They also wanted to be able to automate the entire process to allow for uninterrupted production.  Solution With a deep history of experience to

January 2016

Friction Stir Welding: A Sustainable Solution

POSTED: 01/25/2016

In the automotive industry where fuel economy rules, the mass of a car is an important factor when making a purchase. It takes more fuel and energy to move a heavier vehicle, so new technologies are continually being developed in order to reduce energy and fuel consumption. Now, with the

Automation Reduces Energy Usage for Brewery

POSTED: 01/08/2016

The Customer’s Challenge A major North American brewery required JMP’s assistance on a project that was part of an overall strategy for reducing energy usage. The client operated eight compressors in the powerhouse. Five of the compressors were Vilter compressors previously provided with direct PLC control (on-off with priority and sequencing). The

JMP Makes the Case for Faster Packing

POSTED: 01/07/2016

The Customer’s Challenge A leading Canadian food products company relied heavily on high-speed production lines to support the lower production costs that were key to their competitive pricing strategy. Their aging Pyramid case packer, rated for 5000 cases per eight-hour shift, was experiencing frequent breakdowns. Output per shift had slipped

December 2015

Heavy Diverting in Packaging

POSTED: 12/31/2015

A major dairy packaging company operating multiple plants in Texas and surrounding states had a need to improve the inspection and reject station for their half-gallon gable top carton filling line.  The improvement in the inspection system’s speed and accuracy meant the station would no longer be the

JMP Keeps 1,000 lbs of Parts Moving

POSTED: 12/30/2015

The Challenge The movement of very heavy parts (over 1,000 lbs.) was a challenge for our client, a parts manufacturer. Using manual labour to move these parts was slow and unsafe, and the client needed to automate this process. The JMP Approach JMP worked together with the robot manufacturer to create

JMP's Automation Solution Delivers Plastic Bags in Only Four Seconds

POSTED: 12/28/2015

The Challenge Struggling to meet the demand for their product, our client, a paper and plastic bag fabricator, turned to JMP for help. The manual system they had in place was labour intensive and ergonomically challenging for the workers, and cost too much. The JMP Approach JMP created a material handling

October 2015

Utilizing RTX RTOS Platform to Revolutionize Digital Audio Workstations

POSTED: 10/30/2015

The Market & Customer Profile HMerging Technologies builds state-of-the-art digital audio and video recording and mixing equipment for professional applications that require precise and synchronized playback for a wide array of uses including theater; live events; TV and radio broadcasts; feature film production and post-production; outside broadcast vans; museums; kiosks

Hurco & IntervalZero RTX: Partners in Windows-Based Embedded Real-Time Control for More Than a Decade

POSTED: 10/30/2015

The background and challenges: Hurco is a US-based global industrial automation company that designs and produces interactive computer controls fitted to its machine systems for the metal cutting and forming industries. In 1984, Hurco pioneered and patented the use

Precision Machinery Research and Development Center (PMC) Builds Range of Industrial Robots with IntervalZero’s RTOS Platform and KingStar IO

POSTED: 10/13/2015

Background and Challenges Precision Machinery Research and Development Center (PMC) is a Taiwan-based company created in 1993 by the government and the Association of Machinery Industry (TAMI). PMC has teams of engineers from

September 2015

Picking a Winner

POSTED: 09/23/2015

Placing coins into a coin presentation case insert sounds like an easy thing to do, right? But when the application calls for placing several thousand coins in exact places on moving inserts every day, the task becomes much more demanding. This was the challenge facing engineers at Coatesville, Pennsylvania-based Farason Corporation.

July 2015

University of Sheffield’s Advanced Manufacturing Research Centre (AMRC) Using Robotmaster to Help Students’ Racing Team

POSTED: 07/16/2015

The University of Sheffield Advanced Manufacturing Research Centre

May 2015

Schmalz Lifters Effective at Reducing Injury and Worker Compensation Claims

POSTED: 05/05/2015

In today’s world it is essential that companies run lean and efficient processes while increasing ergonomic and safe work-flows that protect and broaden the work force. Vacuum Tube Lifters are an economical and practical tool for meeting each of these essential goals. In 2010 an independent study conducted at Munster International Airport reported that after one

April 2015

Advanced Temperature Monitoring and Control at Hill Country Bakery

POSTED: 04/15/2015

Control system integrator assists Food Manufacturer in meeting safety and quality goals with the engineering, design, and implementation of an advanced automated temperature monitoring and control system. Auburn Hills, MI - Patti Engineering, Inc., a leader in control systems integration, today announced details of a project it completed for Hill Country

Schmalz large area grippers also excelling

POSTED: 04/02/2015

America’s largest manufacturer of hardwood plywood and hardwood veneer products was able to resolve the issues with their feeder. The new handling solution installed in one of the facilities proved that this advanced gripping technology was the right choice. This is the 3rd generation evolution of Schmalz large area grippers. The

Efficient handling of metal sheets

POSTED: 04/02/2015

Holding force, lateral force absorption, adaptability to the work piece, long life, environmentally friendly design and a clear reduction in costs: With the suction pads series SAXM, the German producer of vacuum technology J. Schmalz GmbH, sets new standards in sheet metal processing. The requirements of the automotive and sheet metal

February 2015

Laser Hybrid Welding with Gantry Robot

POSTED: 02/09/2015

Precision hybrid laser welding is a demanding application with strict requirements for precision and vibration free motion. Laser welding over large work surfaces is even more difficult –

Simple Solutions for Multi-carriage Tracks

POSTED: 02/09/2015

Kawasaki Robotics US

January 2015

Pilz automation system PSS 4000 Monitors Fire Protection System

POSTED: 01/27/2015

Hackensches Quartier, in Berlin, Germany, opted for the Pilz automation system PSS 4000 to monitor their fire protection system.  The building complex spans 44,000 square meters with the industry-proven PSS 4000 monitoring the fire protection system, ensuring that smoke extraction concepts that are triggered will work reliably, thus providing safety

Intuitive Robot Programming for Flexible Aerospace Manufacturing

POSTED: 01/21/2015

Robots are proving to be flexible tools for aircraft manufacturing and assembly. Their full poten-tial however can be limited by the challenges of programming a robot in a CAD/CAM environ-ment. Software that integrates offline programming, simulation, code generation, and path opti-mization makes the process seamless and error-free. Robots are

December 2014

75-ton Turbine Requires Güdel Gantry for Precise Robot Measurement

POSTED: 12/03/2014

The Challenge : Automate inspection of large, complex geometry of a 75-ton turbine Manual inspection of a 75-ton turbine is a time consuming, difficult task that takes teams of workers up to two weeks, requires high levels of precision and is prone to human error. Precision and repeatability are the

March 2014

Intelligrated integrates Alvey robotic and conventional palletizing system to handle Hershey’s wide range of product

POSTED: 03/17/2014

Intelligrated integrates Alvey robotic and conventional palletizing system to handle Hershey’s wide range of product   Please note: Intelligrated acquired Alvey® palletizing products through its purchase of the North and South American operations of FKI Logistex® in June 2009.   At the Hershey manufacturing facility where packaging systems engineer Alex

January 2014

Automated Assembly System

POSTED: 01/09/2014

Midwest Engineering Systems Inc. provided a water outlet assembly system for an injection molding & prototyping company. The final system was a completely automated system that moved unassembled parts through three (3) assembly operations.   The Challenge System

Automated Knurling Machine

POSTED: 01/09/2014

Midwest Engineering Systems Inc. provided a valve plate knurling machine for a metal fineblanking company. This machine is used to fully automate the knurling process for an automotive industry application. The Challenge Machine must be capable of programming four

November 2013

Case Study - Manufacturing, Robotics, Material Handling

POSTED: 11/19/2013

Tech-Con Automation develops robotic rack transfer system utilizing FANUC robots to provide fully automated production. A globally diversified automotive supplier was in need of adding a system to their production line that would increase overall productivity. The purpose of this system was to provide automated component rack

October 2013

Compliance in Motion - an Automotive Parts Application

POSTED: 10/04/2013

Creative Automation, Inc. headquartered in Whitmore Lake, Michigan, provides turnkey automation solutions for industry. The company is in the process of building and commissioning the materials handling systems for eight gear machining work cells for a major automotive parts

September 2013

Tech-Con Automation Recently Implemented the Most Recent Version of INDUSTRIOS

POSTED: 09/23/2013

“Not only did we buy a software solution, but we purchased the expertise of the people from INDUSTRIOS and their implementation team. They’ve really helped us improve how we operate our business today,” Nino LaDuca, General Manager Since its inception in 1995, Tech-Con Automation

How the New PV-JB/MF Open Format Junction Box for PV Modules Came to Light

POSTED: 09/23/2013

Multi-Contact AG, a global electrical connector manufacturer using advanced contact technology, has been active in the solar industry for decades. The company is a pioneer in photovoltaics, having developed the MC3 connector system (the world’s first plug-and-play) as well as the ubiquitous MC4 connector system. Though

Carnegie Mellon Successfully Exploiting Manufacturing Robots with Robotmaster

POSTED: 09/18/2013

Client Profile:   Carnegie Mellon University (CMU) is a global research university with campuses located in Pittsburgh, Qatar and Silicon Valley.  The Carnegie Mellon School of Architecture in Pittsburgh has consistently ranked in the top ten professional architecture degree programs, with a reputation for being

Quad Robot Waterjet Cutting Cell Assists Automotive Client with Increasing Accuracy, Productivity and Quality.

POSTED: 09/17/2013

Our client, a leading global supplier of automotive components and systems, required an increase in production volumes in contour cutting of automotive interior components including periphery, holes and various geometries. Our team’s approach, incorporating FLOW International UHP equipment, was to design, manufacture, assemble, test and install our Quad Robot Waterjet

Tech-Con Proven Robotic Palletizing System Ensures Increased Product Throughput

POSTED: 09/17/2013

A leading North American manufacturer of electrical enclosures required an increase to their product throughput and improved safety features for its workforce. Our team partnered with MOTOMAN Canada to produce a successful solution. CHALLENGES Lack of resources for quick and accurate

Tech-Con Automation Successfully Installs Thermoform FANUC Robot Press Handling Machine to Increase Productivity

POSTED: 09/17/2013

A global supplier of household appliances approached Tech-Con with a requirement to increase their productivity. The client required multiple stacks of incoming product with accurate location to unload and serve a finished part to an exit conveyor thus allowing the finished part to exit the cell and serve the following

August 2013

Robotic Press Break-Automated Metal Bending

POSTED: 08/14/2013

Midwest Engineering Systems Inc. (MWES) provided a Robotic Brake Press Tending System to automate the metal part bending process of a Bystronics Brake Press for a metal fabricator.  The goal is to completely automate the brake press to bend a variety of different parts. The Challenge: Must be capable of

May 2013

Grippers that Hold Up in Extremely Tough Environments

POSTED: 05/10/2013

Bremen Castings, a precision CNC machine shop and foundry located in Bremen, Indiana, has a tough job to do. Producing gray iron castings from recycled material is a job

February 2013

Plastics Unlimited

POSTED: 02/08/2013

ISO 13849-1 IN ACTION: Plastics Unlimited in Preston, Iowa   For most people, the coming of a new year means new resolutions. For many U.S. manufacturers, however, a new year often means new regulations – and this year has been no different. Perhaps one of this

January 2013

Red robots in the house: ABB robots Help a Traditional Black Forest Brewery

POSTED: 01/28/2013

On the production floor, the scene is like one from a delicate and very precise ballet of technology: an ABB robot bends gracefully forward and grips a stainless steel beer keg gently but firmly around its “waist,” then smoothly rotates it 90 degrees and carefully places it, inverted, in the

Robotic Welder Leads Trailer Manufacturer Down Productivity Path

POSTED: 01/15/2013

Arc welding takes on a new look at Titan Trailers as a robotic-welding system takes over high-volume production of aluminum and steel couplers, swing-door assemblies and other weldments.  As a result, productivity and quality have measurably improved. Innovation is the norm at Titan Trailers, a supplier to the hauling

Furniture maker IKEA boosts production capacity with industrial robots

POSTED: 01/04/2013

Office and kitchen furniture manufacturer Spartan, a branch of Swedwood (part of the IKEA Industry Group) in Slovakia, have installed two robotized paint lines to help achieve their

December 2012

Danish Robot Reduces Cost, Optimizes Production at Precision Engineering Company

POSTED: 12/28/2012

Rising wages and the intricate management of the labour force have created a challenging work environment for a Singapore-based company, Sky Engineering. For a long time, this precision engineering company tried to reduce their production costs. They finally succeeded with the implementation of Universal Robots in one of their CNC

Robot Saves Man Years at Dairy

POSTED: 12/28/2012

Iceland's biggest dairy, Mjólkursamsalan Akureyri, uses two UR5 robots in its production of milk products. Their deployment saves the dairy several man years of monotonous work every year. The first UR5 robot was installed in September 2011 in connection with modifications to a cream cheese production line. One

Multi-Application Robot Arm is 'Child's Play' to Programme

POSTED: 12/28/2012

Traditional robots can substantially boost productivity but generally they are large devices that are application-specific and complex to programme.  They need high production volumes to justify both capital cost and integration time.  For a manufacturer new to robotics this can be off-putting and also uneconomical if products and batch sizes

New Robot Lends Precision and Reliability to Production of Hearing Aids

POSTED: 12/28/2012

Hearing device manufacturer Oticon needed a more flexible robot to handle the tiny hearing device components in its production. The company found the ideal solution in the six-axis robot from Danish company Universal Robots. Employing robots in the production process was not a new concept to Oticon. This manufacturer of hearing

A Measuring Robot Ensures “Just-in-Time” Assembly

POSTED: 12/28/2012

In automotive supplier Lear Corporation’s demand-led production, robot arms from Universal Robots play a crucial role: The lightweight robots assemble car seats by locating, measuring and tightening screws on car seats resulting in shorter throughput time and greater process reliability. Just-in-time assembly is an established production model in the

October 2012

Multi-Contact 10BV Connectors Used to Ensure a Reliable and High-Power Battery Connection in Electric Vehicles

POSTED: 10/25/2012

Business needs – Background A manufacturer of electric vehicle conversions offering  a wide range of products, from small cars to large busses. 

Data Transfer Modules Add to Versatility of Multi-Contact Connector System

POSTED: 10/25/2012

Part of modular CombiTac connector system, contact carriers are available for Ethernet cabling and field bus systems. CAT 5 IEEE 802.3 Ethernet types have 2 RJ45 sockets connected to 8-pole, gold-plated plugs or sockets on opposite side. CT-NET bus types, rated CAT 6, can hold one or two 8-pole, male/female

Fused 1000 V Test Leads from Multi-Contact Assist Operator Safety

POSTED: 10/25/2012

UL approved test leads are terminated with 4 mm diameter plugs for connecting standard safety test clips and probes to enable safe, fuse-protected measurements. They accept 6.3 x 32 mm UK style fuses, which can be fitted by unscrewing 2 part connector. Available with PVC/silicone insulation, leads are fitted with

Magnetic Adapters Accelerate Safe Connection of Test Leads

POSTED: 10/25/2012

Used where clamping is not possible, magnetic adapters safely attach test leads onto screw heads. Adapter tip consists of bar magnet between 2 steel poles for optimal adhesion, and slightly concave shape of magnetic tip ensures optimal contact. Two versions are available, with 7 or 11 mm dia magnets, and

The Modular Power Connector (MPC) from Multi-Contact Combines up to 15 Single-pole Power Contacts

POSTED: 10/25/2012

The great advantage is obvious: the modular design permits the construction of application-specific plug connectors with standard modules. Fixed mounting dimensions with variable assembly configuration simplify structural integration. That reduces costs for logistics, warehousing and service. Applications can be found in regional rail, subways and streetcars, but also

Shielded Round Connectors 16BV-GS und 21BV-GS for high-power applications

POSTED: 10/25/2012

As a customer-specific solution, Multi-Contact has developed fully shielded connectors for power supply with frequency converters, e.g. for operating three-phase motors. The 16BV-GS and 21BV-GS connectors are suited for applications in deep drilling rigs for geothermal exploration, in energy supply chains for crane systems as well as in all applications

Metal Coating Painting Application Without Masking

POSTED: 10/04/2012

Faverges (France) - At the beginning of 1998, AXO-SCINTEX in France launched a new production line for the manufacturing of the PEUGEOT 206 taillights. Since 1985, this company has been producing lighting and signaling equipment for the automotive industry. More than 150 employees working around the clock, are involved in this

July 2012

Mechatronics Ping-Pong Project Challenges University Students

POSTED: 07/25/2012

Application: Mechatronics university robotics team project Industry: Education Problem: Macron Dynamics regularly works with young student engineers and robotics teams at the university level to provide support and/or products at little to no cost. We believe in helping these budding engineers, and our application engineers enjoy jumping into

May 2012

KP Foods Palletizing

POSTED: 05/22/2012

TASK KP Foods Plant at Stockton-on-Tees is a manufacturer of Potato Crisp snack foods. The end of line process involved a manual palletizing process of the boxes of Crisps. This needed a high number of personnel over three shifts operating 24/7. KP wanted to

Improving Accuracy with Quad Inverted Robot Waterjet Cell

POSTED: 05/17/2012

Client Saves Cost and Improves Accuracy with Quad Inverted Robot Waterjet Cell   Tech-Con Automation helps automotive customer cutting carpets to increase accuracy.   Our client is an automotive carpet manufacturer that required a method to cut the carpet into appropriate shapes in a way that was fast, accurate, and

Palletizing Two Different Product Lines with MOTOMAN MPL160

POSTED: 05/17/2012

Client Palletizes Two Different Product Lines Using a Single MOTOMAN MPL160 Robot Cell   Mississauga, Ontario manufacturer saves space by palletizing two different lines with one robotic palletizing cell.   Our client is a producer of margarine. They package two

January 2012

Chocolate Bars Uniquely Packaged

POSTED: 01/12/2012

Packaging containers can sometimes be quite elaborate. Although you rarely hear consumers ask themselves how the products in their shopping cart got into their packaging, this extremely interesting process continuously spurs packaging machine manufacturers to innovate. The faster, the better, the more accurate so as not

Combination of Robots and CDLR Conveyors Increases Production Up-Time

POSTED: 01/05/2012

Tech-Con Automation combines Robots and CDLR conveyors to Increase Production Up-Time A Tech-Con Automation client is a Tier 1 manufacturer of engine cradles. The client required an automated way to handle cradles going into and coming out of a protective coating process prior to shipping. CHALLENGES Part

October 2011

A Lean-Mean Welding Cell

POSTED: 10/11/2011

…pairs a material-handling robot to manipulate weld fixtures with a robotic welder. Together the robotic duo tackles multiple part configurations and small batch sizes. Healthcare-product manufacturer Midmark Corp, knows robotic welding inside and

Fast Forward for Image-Based ID Readers

POSTED: 10/11/2011

VSoC-powered readers increase read rates, reduce downtime and speed setup In the not-so-distant past, manufacturers using laser scanners and conventional area-scan image based readers had to put up with inherent technology limitations. Laser scanners, for example, have a hard time reading barcodes through plastic shrink-wrap, barcodes printed on flexible

August 2011

Weber Aircraft

POSTED: 08/31/2011

Client Profile: Weber Aircraft LP, a subsidiary of The Zodiac Group of France, is one of the leading manufacturers of commercial aircraft seats for airlines and major aircraft manufacturers worldwide. The Company manufactures a wide variety of commercial aircraft seats, ranging from ultra-luxurious first-class “lie-flat”

Machining Robots Bring Stone Mason's Skill to the 21st Century

POSTED: 08/31/2011

The latest robotic technology, state of the art processing equipment and an environmentally friendly, healthy and safe business approach are not what might be readily associated with the stone quarrying industry, but at JWQ (Johnson Wellfield Quarries) in Huddersfield investment in new facilities and a desire to

General Atomics Aeronautical Systems

POSTED: 08/31/2011

Client Profile: General Atomics Aeronautical Systems (GA-ASI) is a leading manufacturer of unmanned aircraft systems (UAS) and tactical reconnaissance radar, including the Predator UAS series and the Lynx SAR/GMTI sensor systems. The company is dedicated to providing long-endurance, mission-capable aircraft with the integrated sensor and datalink systems required

Flow Automation

POSTED: 08/31/2011

When robots first came on the manufacturing scene in the late 1950s and early 1960s, skeptics accused them of stealing jobs and dehumanizing the workplace. Others thought robots could solve the industrial world’s woes. Today’s truth: We’ve only just begun to realize the robot’s true potential. Contrary to

AV&R Vision & Robotics

POSTED: 08/31/2011

Client Profile: AV&R Vision & Robotics is a leader in industrial automation, offering intelligent automation solutions to optimize manufacturing processes and to control quality. The Company has developed a broad range of expertise in enabling robots to perform complex tasks that traditionally could be performed only

Armatec Survivability/Ottobock Healthcare

POSTED: 08/31/2011

Precise, reliable cutting and machining centers; words not often used to describe industrial robot arms. Robots are often disvalued in manufacturing circles as being inaccurate. Citing tolerances of +/- 0.100 (or more), robots are often dismissed as only suitable for welding or pick and place applications.With better initial accuracy from

Rexroth VarioFlow conveyors offer modular advantages for Oak State products from wrapping, to cartoning, to case packing

POSTED: 08/30/2011

Easy-to-assemble modular approach adds both packaging capacity and flexibility for food products customer needs When food product consumers’ tastes change, food product manufacturers’ processes need to change with them, to stay ahead in a competitive marketplace. That’s where Oak State Products, a Wenona, Illinois-based contract packager and manufacturer of baked goods,

April 2011

Mining Equipment Manufacturer Digs Robotic Welders' Productivity

POSTED: 04/18/2011

Four long-armed heavy-metal welding robots lay down 150 lb. of filler metal over several weld passes to help mining-equipment manufacturer Bucyrus Corp. take its armored-face conveyor line to the next level in toughness and durability. You’d be hard-pressed to find more rugged machinery than that used

February 2011

Automation with Dexterity at the Robotics Competence Center of the WIFI OÖ

POSTED: 02/07/2011

Recently introduced by KEBA, the active contact flange for sensitive automation tasks has been in use in practical application since January 2011 at the Robotics Competence Center of the WIFI Upper Austria in Linz. Recognised throughout Austria, the WIFI (Wirtschaftsförderungsinstitut) or Economic Development Institute is an institution with numerous

Product Handling Put to the Test at Twizzlers Candy Plant

POSTED: 02/07/2011

Twizzlers® candy from Y&S Candies, Inc., a division of The Hershey Company, is an American candy favorite, known for its sticky, pliable consistency and sweet fruity flavors. However, some of the qualities that make it such a satisfying treat also make it a product packaging challenge. Y&S produces and

January 2011

Palletizer Robot Uses Common PLC Platform

POSTED: 01/03/2011

New robotic palletizer from Intelligrated uses an Alvey robot that is controlled via a common programmable logic controller (PLC) platform. This alternative to the traditional proprietary robot controller improves line integration, response time

November 2010

One Multitasking Robot, Two Heavy-Lifting Jobs

POSTED: 11/19/2010

This is one busy robot, working on one side of a manufacturing cell to case-pack, and then swinging around to palletize the heavy cases. Operators are spared the heavy lifting, and throughput has climbed by 35 percent. As sales climbed dramatically for 21.5-lb. bulk plastic bottles of windshield-washer fluid

Flexible Cable Performs in Severe Cold Temperature Environments

POSTED: 11/01/2010

  Problem: A leading North American manufacturer of electric fork lift trucks wanted a rugged flexible cable that could not only withstand thousands upon thousands of flexes year after year, but also endure extreme sub-zero temperatures in working environments where the fork lift equipment is used to offload foods and perishables from

September 2010

Alvey Robotic Palletizers from Intelligrated Paint a Picture of Efficiency for Kelly-Moore Paint Company

POSTED: 09/01/2010

Willingness to Invest in Future Yields Big Dividends With 76% Return on Investment in First Year. The Company Beginning in 1946 with a single manufacturing facility in San Carlos, California, Kelly-Moore Paints™ has grown to the largest employee-owned, and the 5th largest paint company, in the United States. Supporting over 165 local

June 2010

KMT Robotic Solutions responds quickly to repair flood damaged robotic system at Tier II supplier

POSTED: 06/22/2010

On Saturday, May 1, 2010, the Cumberland River overflowed its banks and caused extensive flooding in Nashville, TN. For three (3) days a Tier II supplier

Injection Molder Gets Robotic Automation Right the First Time

POSTED: 06/01/2010

…and every time thereafter. Employing robots to automate repetitive machine-tending tasks has provided Nyloncraft Inc., an injection-molding contract manufacturer, the flexibility to add labor in key areas where it was needed to support growth, without having to hire new employees.  So says Nyloncraft

May 2010

Sliding Slewing Ring Bearings

POSTED: 05/24/2010

Rotary motion on an ultrasonic welding machine  EAST PROVIDENCE, R.I. – A developer and manufacturer of custom-made equipment for the fabricating industry uses sliding slewing ring bearings from igus® for rotary motion on an ultrasonic welding machine. iglide® PRT slewing ring bearings facilitate movement on both the X and Y

Tray Loading Robot

POSTED: 05/05/2010

Customer Information – ASCO Sintering is an employee-owned company and is a leader in the design and manufacturing of powdered metal products. For the past 50 years, ASCO Sintering has maintained strong relationships with several Fortune 500 companies in

April 2010

Centerless Grinder Automation

POSTED: 04/30/2010

Customer Information - The customer runs a precision machine shop manufacturing a great variety of parts for the industrial, commercial and aerospace markets. Part volumes are low to medium. Application - Automation of a Royal Master TG - 12 manual centerless

A Sweet Success Story: Candy Factory Modernizes its Robotic-Palletizing Cells

POSTED: 04/22/2010

The Hershey Company licorice plant welcomes new palletizing robots—along with controls and simulation software--to handle 85 percent of the plant’s palletizing chores, while also increasing productivity, flexibility and reliability. Since April 2009, the Y&S Candies plant in Lancaster, PA—home of the Twizzler—has been busy upgrading its four 20-yr-.old robotic case-palletizing cells,

Plastic Plain Bearings for Ski Bindings

POSTED: 04/16/2010

EAST PROVIDENCE, R.I. – A Colorado-based manufacturer has incorporated iglide® plastic plain bearings from igus® into its high-end, telemark ski-bindings, which has both created a more reliable product and virtually eliminated maintenance requirements. Defective ski-bindings risk the health and life

January 2010

Katayama American Company Automates In-Line Measurement

POSTED: 01/20/2010

Problem: Katayama American Company, Inc. (KACI) came to Dynalog with the following challenge:  Integrate a robot from Motoman and 3D sensor from LMI to perform 100% in-line inspection of up to 12 features on each of the

December 2009

Classic Metal Finishing: Robot Provides Increased Production and Flexibility…A Robot Case Study

POSTED: 12/07/2009

Classic Metal Finishing, based in Jackson, Mich., is a supplier of components for the aerospace, motorcycle, racing, and medical industries. The plant was purchased in February, 2008 by Classic Metal Finishing and Classic Turning.  Classic Turning performs high-end CNC machining of components and Classic Metal Finishing performs anodizing and dry

October 2009

Handling Hot Work Pieces with Vacuum Suction Cups

POSTED: 10/15/2009

The Challenge A leading specialist for injection molding and assembly technology for vehicle interiors has to take out hot work pieces from the injection-moulding machine and place them on a conveyor.  Specifically: internal door handles for automobiles. The parts have a temperature of 176

September 2009

Pre-Harnessed Cable Carriers Withstand High Speeds and Accelerations

POSTED: 09/23/2009

500,000 cycles per year EAST PROVIDENCE, R.I. – August 13, 2009 – Jessup Engineering uses pre-harnessed cable carriers from igus® on its overhead hoists for the metal-finishing industry. The cable carriers replace umbilicals, which were not suitable

July 2009

Robotic Submerged Arc Welding

POSTED: 07/02/2009

INDUSTRY Cast Iron Pipe PROJECT NAME Thrust Collars PARTS Ductile Iron Pipe CUSTOMER BENEFITS Automates the subarc welding process Adapts weld program to part variations Controls all aspects of the production cycle Improves product quality and consistency Tracks service and maintenance requirements SYSTEM OVERVIEW The welding cell

Robotic Automated Welding Station

POSTED: 07/02/2009

INDUSTRY Agriculture PRODUCT Chopper blades for hay baler BENEFITS Automates the welding operation Reduces manufacturing process cycle time Improves product quality Minimal tooling requirements Less operator involvement SYSTEM OVERVIEW The welding cell consist of one IRB 2400L welding robot and one IRB 4400 material handling robot. In addition there is an IRBP 250A

Robotic Plasma Cutting

POSTED: 07/02/2009

BENEFITS High speed cutting Less heat-affected zone Cuts all metals including aluminum and stainless steel Produces quality bevel cuts for welding Follows part/shape contours Minimal cleanup Reduced part warpage Process versatility using tool changers PROCESS OVERVIEW Plasma cutting is a process where an ionized gas conducts electricity creating a hot, energized

June 2009

Material Flow Solution - Thorough Rationalisation in Production and Distribution is an Absolute Necessity

POSTED: 06/02/2009

Since expensive production machines can be run in three shifts only if the automation is integrated, particular attention must be paid to the periphery and, above all, the gripping systems.   Schmalz is the world's leading partner for vacuum gripping systems in automation technology. Innovative and complete vacuum automation systems

May 2009

At Spinic Manufacturing, Robots Rail Against Recession

POSTED: 05/17/2009

Spinic Manufacturing, a Division of Linamar

April 2009

Deployment of Robots Within Insert Molding Workcells Results in Dramatic Improvements

POSTED: 04/29/2009

Every year products are being made smaller and smaller and tolerances become tighter and tighter. And when you add the need to meet strict safety-code requirements, it becomes a formula for finding new ways to

Plastic Bearings Offer Major Cost Savings

POSTED: 04/24/2009

Plastic bearings replace bronze in camera jibs for the film industry EAST PROVIDENCE, RI – April 24, 2009 – EZ FX uses iglide® plastic plain bearings from igus® on its camera jibs for the

Speeding Up During Global Slowdown

POSTED: 04/21/2009

Introduction The competitiveness among companies in the highly automated metal fabrication industry is tough in these days of global economical slowdown. Efficient production along with a high output of the line(s) is crucial for the plants. Plants with low productivity will quickly

Cable Carriers Eliminate Costly Maintenance

POSTED: 04/15/2009

Cable carriers replace festoons on automated storage and retrieval systems EAST PROVIDENCE, R.I. – March 27, 2009 – Weldon Solutions uses plastic cable carriers and continuous-flex cables from igus® on its automated storage and retrieval systems for the baking industry.  They replace festoon systems that required more space and

March 2009

Motion Control System Controls and Automates Packaging Machines

POSTED: 03/31/2009

Overall motion management  Packaging machines in the pharmaceutical sector are demanding: they have to be reliable, modular and versatile, but most of all they have to be flexible and efficient. The requirements of the corresponding drive

Modern Safety and Control for Packaging

POSTED: 03/31/2009

Safe interaction between man and machine   Faster, more flexible, safer – with this objective in mind, the level of automation on plant and machinery

February 2009

Arctic Snow & Ice Control Plows up Productivity with New Robotic Welding Cells

POSTED: 02/18/2009

Founded in 1978 as a contract snow and

Low Cost Bearings for High-Speed Scanning

POSTED: 02/09/2009

Imaging Business Machines LLC (IBML) uses iglide polymer plain bearings in its line of intelligent document-scanning platforms. The low-cost, self-lubricating bushings withstand the paper dust created by the scanners and the six-day, 24-hour operation schedules frequently demanded of them. IBML’s

Bearing Up in the Packaging Industry

POSTED: 02/09/2009

Matrix Packaging Machinery, a primary packaging equipment manufacturer, implemented maintenance-free DryLin R linear bearings on its packaging machines after recirculating ball bearings caused shaft damage and grease leaks. Matrix manufactures form fill and seal packaging equipment to handle

A Smoother Ride with Plastic Bearings

POSTED: 02/09/2009

Straitline Components, a manufacturer of precision pedals for biking hobbyists and extremists, employed lubrication-free iglide G300 bearings after roller bushings caused premature wear and failure for its customers. Straitline manufactures a wide range of bicycle pedals and parts from

24-Hour Schedule No Problem for Linear Guides

POSTED: 02/09/2009

Schneider Packaging Equipment Co. Inc. uses maintenance-free DryLin W linear guides in a custom packaging machine used to box up four cases of plastic bottles per minute, 24 hours a day. The linear guides replace standard slotted brackets and act as a vertical guide for the machine’s grabbing device.

January 2009

November 2008

Robots Speed up Flashlight Assembly, Cut Costs

POSTED: 11/13/2008

SureFire LLC, located in Fountain Valley, Calif., is a manufacturer of professional-grade, high-intensity flashlights. The extra-rugged, extra powerful flashlights are used in a variety of demanding applications. Although much of the flashlight assembly process was already

October 2008

OLP/SIMULATION

POSTED: 10/16/2008

Since implementing offline programming, and then refining the process, Johnson Controls, Inc. has dramatically reduced programming costs wile improving production uptime in its robotic waterjet-cutting cells.  JCI reduced line utilization for programming purposes by 96 percent, from 50 hours to 2 hours, with an 82

Three Robots Perform Tandem-arc, Heavy-deposition Welding on Manitowoc Cranes Outriggers

POSTED: 10/01/2008

Manitowoc Cranes recently implemented a unique triple robot tandem-arc welding automation solution in its Shady Grove, Pennsylvania factory to solve several common challenges faced by many U.S. manufacturers today.  Despite a shortage of skilled

August 2008

Routing system reduces race kit car cost and improves quality

POSTED: 08/28/2008

Challenge Factory Five Racing, Inc., was faced with the challenge of trimming fiberglass and plastic reinforced kit car panels by hand using routers and trim fixtures. The hand trimming process and accidental fixture movement created inconsistencies in quality and contributed to a high reject rate. Solution KMT Robotic Solutions responded to

Waterjet Stripping System helps GE reduce cost and improve productivity

POSTED: 08/28/2008

Challenge For the past 12 years, GE Strother used a waterjet stripping machine with a closed loop filtering process to remove thermal sprayed coatings from jet engine components. Thermal coatings, made of ultra-fine grained metal alloys or ceramics, are applied to protect the base material of components that are exposed

Router Trimming system produces Class A surfaces

POSTED: 08/28/2008

Challenge Durakon Industries, headquartered in Lapeer, Mich., is the world’s leading supplier of vehicle protection and cargo management systems for original equipment manufacturers and the aftermarket. In trimming a variety of large, molded in color automotive exterior trim components, Durakon needed a robotic router trimming solution that could meet the

Robotic Welding at LB Steel/Coburn Steel Products Improves Quality and Productivity

POSTED: 08/20/2008

Many fab shops in the U.S. are getting pounded by foreign competition, but LB Steel, LLC/Coburn Steel Products is successfully fighting back -- thanks in part to robotic welding. 

Trimming challenging materials with waterjet

POSTED: 08/11/2008

Challenge Plastics Unlimited is an Iowa-based company that manufactures custom thermoformed products including automotive and recreational vehicle trim, shipping pallets, packaging materials, covers and shrouds. Plastics Unlimited has also developed a unique,

Carbon Fiber Part Router Trimming

POSTED: 08/11/2008

Challenge PlasanUSA, a Vermont, USA, based manufacturer of custom carbon and fiberglass composite automotive components, is a major supplier of automotive fenders, hoods and roof panels for leading American sports cars. When Plasan (then Vermont Composites) won the business

July 2008

Precise Control of Force

POSTED: 07/09/2008

Systems developed by Sandia's Intelligent Systems and Robotics Center (ISRC) often require precise control of the forces applied. Developers add load cells to robots to sense force and moment. These load cells are called six-axis force-torque sensors because they must accurately and separately measure all

Nuclear Scientists in Australia Choose Pilz PSS to Safeguard Facility and People

POSTED: 07/07/2008

(CANTON, MI) - No other Australian safety system faces the intense scrutiny as that focused on the country's nuclear reactor and, arguably, no Australian workplace takes safety more seriously. So, when some of the world's most brilliant scientists use a new Australian Nuclear Science and Technology Organization (ANSTO) experimental facility,

June 2008

Brewery is More Competitive with Robotic Packaging and Palletizing System

POSTED: 06/01/2008

Problem: Medium-sized breweries can survive in a tightening market only with mature marketing concepts and unusual product ideas. The packaging industry, too, is being put more and more to the test by the segmentation of

FANUC System Sorts and Palletizes Eight Different Products Simultaneously

POSTED: 06/01/2008

Problem: Jefferson Smurfit Corporation, headquartered in St. Louis, Mo., is one of the nation’s most broadly based paper, paperboard and packaging companies.  It is also the nation’s leading collector, marketer, recycler and exporter of waste paper. A product line

FANUC Palletizing System Reduces Labor Costs at Alto Dairy

POSTED: 06/01/2008

Problem: Waupun, Wisconsin-based Alto Dairy faced significant costs related to strains and injuries suffered by workers required to palletize over 7,600 cases of cheese per eight hour shift.  In addition, the repetitive manual palletizing job was boring

Easy Does It: Robotic Packing and Palletizing of Lightbulbs

POSTED: 06/01/2008

Problem: A lightbulb manufacturer faced intense pressure to produce high-quality, reliable products while keeping consumer costs low. In this extremely competitive market, this manufacturer needed to maintain production uptime, improve reliability and minimize product damage.  To meet

A Turn for the Better -- Gripper Extends Robot's Work Envelope

POSTED: 06/01/2008

When packaging stamped parts, a KUKA robot reaches out beyond its "natural" work envelope - an advantage which makes investment in a larger robot unnecessary. This cost-effective solution is based on an eccentric gripper by means of which the carrier being used can be filled all the way to the

Painting the Stealth

POSTED: 06/01/2008

U.S. F-117A Nighthawks, also known as Stealth fighters, swoop largely undetected through radar because their "radar-invisible" paint and angular exterior minimize reflected signals. Over the next few years, the fleet of F-117As will be refurbished, including removing the aging thin films and

May 2008

RobotWorx Used Robot Finds a Home in Columbia, South America

POSTED: 05/18/2008

Fanalca S.A. is a motorcycle assembly and manufacturing company for Honda located in Cali, Columbia. Thanks to RobotWorx, a robotics integrator based in Ohio, they were able to install their first welding robot. Fast service, low cost robots, and a strong Internet presence

Robots Weld Round Baler Rolls at New Holland Plant

POSTED: 05/05/2008

The New Holland Agriculture plant in New Holland, Pennsylvania, manufactures a wide variety of agricultural equipment, including the round baler.  Until recently, roll weld assemblies, which help form the bale, were welded on a

April 2008

Custom Injection Molder Chooses Zero-Backlash Robots

POSTED: 04/22/2008

When Triple S evaluated robots for future expansion of automated cells in their factories, they selected a robot as much for what it doesn't do as for what it does do. No backlash. 'If a robot over-accelerates between positions, when it stops it has to 'find itself' which causes it to

Experience Leads to Success

POSTED: 04/20/2008

MOHR (Germany) - This plastics and metal working company uses Stäubli 6-axis-robots in fully automated cells for metal gearshaft coating and printed circuit boards, as well as in fully automated assembly cells for heated windshield wiper nozzles for the automotive industry. Six Stäubli robots - models RX130, RX90, RX90 L

Fully Automated Inspection for Surgical Implants

POSTED: 04/18/2008

100% inspection and identification is essential for most products. Low-volume production often goes hand-in-hand with high costs, particularly if the variety of products concerned is also extensive. DePuy Spine (a Johnson and Johnson company based in

March 2008

Robotic Workhorse Rides Rails at Applied Engineering

POSTED: 03/18/2008

Applied Engineering, Inc. (Yankton, SD) manufactures precision machined aluminum components and assemblies for a broad range of applications in aerospace, defense and commercial applications.  ISO 9001, AS9100 and NADCAP certified, the company prides itself on innovation and use of cutting-edge automation to produce high-quality

October 2007

Small FAB & Machine Shop Gets Big Results with Robots

POSTED: 10/10/2007

‘‘It would take four men to keep up with one of our new robotic welding cells,’‘ says Matt Tucker, Project Engineer in charge of all robotic applications at Tucker’s Machine & Steel Service Inc. in Leesburg, Florida.  ‘‘People get tired and bored welding thousands of the

August 2007

Flexible Deburring Tool Helps Aluminum Caster Economically and Safely Remove Flashing

POSTED: 08/17/2007

  ‘‘Flashing on die cast parts must be removed for operational, safety and aesthetic reasons, but how this chore is completed has always come under considerable scrutiny by manufacturing engineers and more important Occupational Safety and Health Administration (OSHA) regulators.  With the new, patented Flexdeburr™ tool we

Auto Supplier Adds Handling Robots; Fully Automates Assembly of Engine Manifolds

POSTED: 08/10/2007

  Keihin IPT Mfg, Inc. (KIM), a Tier-One automotive supplier of fuel and air management systems for a leading Japanese automaker, is no stranger to robotic automation.  This subsidiary of Keihin Indiana Precision Technology, Inc, (KIPT) implemented their first robot into their die casting area in 1988

July 2007

Bosch Rexroth Helps Semiconductor Equipment Company Lower Costs, Simplify Purchasing

POSTED: 07/16/2007

  Semiconductor manufacturing is probably the most exact manufacturing activity in the world. Companies are using expensive, precise machinery to produce semiconductor wafers whose features will soon be measured down to the thickness of atoms. The latest generation of processing equipment uses round silicon wafers 300 mm in diameter and achieves line

March 2007

Robotic Welding Buoys Launch of Sturdier Examination Tables

POSTED: 03/09/2007

  Midmark Corporation introduces new feature-laden examination tables by banking on robotic resistance welding to provide a cost-effective method to construct an aesthetically pleasing, yet strengthened, cabinet assembly. In 2003 the marketing team at healthcare-product supplier Midmark Corp., based in Versailles, Ohio, challenged its manufacturing team to develop

December 2006

Robots Rack Up Productivity at Tru-Form

POSTED: 12/14/2006

  Founded in 1932, Tru-Form Steel and Wire, Inc. (Hartford City, IN) is a third-generation, family-owned and operated full-service fabrication company that now employs 100 people.  Two Tru-Form plants in Hartford City and one plant in Muncie all use robotic automation to fabricate and weld a wide variety of returnable

November 2006

NASA Perfects Orbital Docking Here On Earth With Help Of Robotics

POSTED: 11/30/2006

  Space exploration and research usually calls to mind images of weightlessness and advanced technologies. But a great deal of engineering takes place right here on Earth, on the ground. Due to the high cost of failure in space and the inherent danger involved, NASA performs exhaustive tests and simulations of

September 2006

Engineered Machined Products: A Company Standing the Test of Time in Michigan’s Upper Peninsula

POSTED: 09/19/2006

Engineered Machined Products (EMP), based in Escanaba, Mich., is a Tier 1 supplier to major diesel engine manufacturers.  It is hard to imagine that such a successful and high-tech manufacturing operation is located in the natural beauty of Michigan’s Upper Peninsula, but it’s there, and if

Engineered Machined Products: A Company Standing the Test of Time in Michigan’s Upper Peninsula

POSTED: 09/19/2006

Engineered Machined Products (EMP), based in Escanaba, Mich., is a Tier 1 supplier to major diesel engine manufacturers.  It is hard to imagine that such a successful and high-tech manufacturing operation is located in the natural beauty of Michigan’s Upper Peninsula, but it’s there, and if

Robots Help Alpine Achieve Peak Performance, Productivity

POSTED: 09/19/2006

With demand for their truss fabrication equipment and other technology-driven products and services for the building components industry skyrocketing -- Alpine Engineered Products, Inc.’s Equipment Division was unable to build the industry-leading company’s AutoMills and Roll-A-Master  systems fast enough.  Due to long lead times, Alpine began

August 2006

Robotic Tape Application

POSTED: 08/16/2006

  Product or Part Automated: Side Body Molding Robot Vendor: Fanuc Robot Model or Type: M16i Robot Integrator: Two Stage Innovation Submitted by: Terry Sharp PEng Company: Two Stage Innovation Inc. Contact: terry@twostage.com Problem Statement Customer wanted a flexible tape application system for a variety of parts. Idustry search along with other

June 2006

Robotics Partner with AGVs to Increase Production Flexibility and Speed
QComp Technologies, Inc.

POSTED: 06/06/2006

Manufacturers in the United States, in attempting to remain competitive in a global economy, often reach for technology to help improve production efficiency and reduce labor costs. For many companies, that technological boost comes in the form of robotics. And one area that is paying the most

January 2006

US Chemical Automates Case Packing With Robotics

POSTED: 01/17/2006

A robotic cell that packs chemical containers into cardboard cases is eliminating repetitive manual operations at a US Chemical plant in southern Wisconsin. The system, designed by Promatech, LLC, New Berlin, Wisconsin, was integrated with the plant’s existing filling, capping and conveyor system and incorporates a

December 2005

Automotive Stamping Study at DaimlerChrysler Finds New Vacuum Technology Elicits Potential Annual Savings of $400,000/plant

POSTED: 12/14/2005

  Summary A recent comparative vacuum technology study performed by Dr. Kingman Yee, as part of a DaimlerChrysler Summer Intern Professors Program, found that air consumption could be reduced by 98% when equipping a robot’s end-of-arm tooling with COAX® technology and a Vacustat™ check valve.  The study

July 2005

Noxzema/Olay Reduces Costs by Using Robotics

POSTED: 07/05/2005

Cosmetic jars and bundles of lids are automatically palletized and stretch wrapped, saving time and labor. The ROI was realized within 18 months. Stretch-wrapped pallet loads of Noxzema and Olay skin care jars and lids have just come off the palletizing line at Wheaton Pharmaceuticals.

June 2005

PIAB’s Vacuum Gripper System Plays Key Role in Robotic Tote Assembly Solution

POSTED: 06/28/2005

Flexible End of Arm Tooling Cuts Costs and Prevents Injuries The Challenge: Developing a Cost Effective and Ergonomic Tote Assembly Solution Due to a number of economic and social factors, including the advancements in automation technology, the rise in overseas manufacturing and the increased awareness of employee safety, the robotic industry

February 2005

At the ‘‘Fore-Front’‘ of Automation: Acushnet Uses Robot to Handle Golf Balls

POSTED: 02/05/2005

Robots and Titleist golf balls might seem an unusual pairing.  However, Acushnet Company (Fairhaven, Massachusetts) -- the leading producer of Titleist® and Pinnacle® golf balls,  Titleist® and Cobra® golf clubs, FootJoy® shoes and gloves, and other golf-related equipment and accessories -- is at the ‘‘fore-front’‘ of golf-ball manufacturing technology,

January 2005

Robots Provide Flexible Automation at AZ Automotive Corp.

POSTED: 01/31/2005

AZ Automotive Corp. in London, Ontario, Canada, is ‘‘spot on’‘ when it comes to robotic processing of the approximately 150 different automotive stampings and assemblies the company manufactures for GM/CAMI and Mitsubishi.   Most components are auto body reinforcements, such as body sides, cowl tops, impact beams,

Shell Solar Implements Robotics to Increase Productivity

POSTED: 01/27/2005

Fossil fuels giant Shell Oil Company investing in solar energy? To most people, the two mix about as well as oil and water. After all, the Shell brand brings to mind a company with a strong heritage of sprawling oil refineries,

November 2004

Trans-gun Tool Changing

POSTED: 11/29/2004

  Reprinted by permission from Robotics World Magazine Robotic spot welding has become the metal joining method of choice in many manufacturing operations, primarily the production of automotive body parts. To keep robots flexible and make the best use of limited floor space, robotic tool changers for trans-gun resistance

October 2004

Machine Vision and Industrial Robots: A Powerful Team

POSTED: 10/05/2004

Machine Vision and Industrial Robots: A Powerful Team Reprinted by Permission from Robotics World Magazine (Posted 10/05/2004) While robotic assembly applications have increased in both number and complexity over the years, a large number of applications have been passed over due to technology.

September 2004

Robotic Bag Palletizing System Helps Forbes Chocolate Productivity

POSTED: 09/17/2004

Forbes Chocolate is a supplier of blended cocoa and flavorings used in the food industry. Forbes blends are used in products such as milk, ice cream, soft serve, frozen yogurt and baked goods. Based in Cleveland, Ohio, Forbes Chocolate is a unique company

July 2004

RELIABOT PC Adhesive Inspection

POSTED: 07/29/2004

RELIABOT® PC Adhesive Inspection is a complete, packaged solution for inspecting the bead of adhesive, sealant, foam, or other material around the perimeter of a part. The solution consists of a bundled Panel PC, Cognex Frame Grabber card, Opto-22 I/O card, Sony cameras, Tectivity

June 2004

Innovative Robotic Laser Cutting And Heavy-Part Material Handling Helps A Leading Automotive Supplier Reduce Operating Costs And Increase Production Flexibility

POSTED: 06/04/2004

  UPF, Inc. is a leading supplier of truck and bus frames to the automotive industry.  Based in Flint, Mich., UPF supplies thousands of truck and bus frames to its automotive customers each year.  A key to UPF's success is its ability to deliver small, medium and large batch runs of

ToyMaker 3000

POSTED: 06/03/2004

What is one of the most sophisticated Computer Integrated Manufacturing (CIM) assembly factories doing at a Museum?  ToyMaker 3000, now open permanently at The Museum of Science and Industry (MSI) in Chicago, produces an assembled Gravitron toy top at a rate of

May 2004

Handling Die Castings In A Harsh Environment

POSTED: 05/01/2004

Handling Die Castings In A Harsh Environment (Posted 04/30/2004) AMCAN (Hamilton, Ontario) was founded in 1936 and has grown to include four additional, ancillary companies, both in Canada and Latin America.  Today, the AMCAN group of companies is a highly

April 2004

Vacuum Gripper System Meets Increasing Demands for Handling Packages of Varying Shape and Size

POSTED: 04/16/2004

The use of robots for placing products in containers, transferring those containers between different stations in the packaging lines and palletizing them is becoming increasingly prevalent in all industries. Robots, with their ability to use a variety of end-of-arm tools [EOAT], provide the high-speed ‘‘pick and place’‘ palletizing ability needed to

February 2004

SIG Delta Robots Get to Grips with Wagner's Piccolinis Pizzas

POSTED: 02/04/2004

Manufacturer of frozen foods, Wagner, was recently met with increased demand for its ‘‘Piccolinis’‘ pizzas. To meet this demand, Wagner turned to SIG Pack Systems for a faster and more efficient production process, which offered a compact solution with a lower level of complexity. Wagner introduced Piccolinis

Stäubli Six Axis Robots Benefit Cell Phone Assembly

POSTED: 02/04/2004

Company:  Stäubli Corporation Industry:  Consumer Goods Application:  Assembly Product or Part Automated:  Cell phones Robot Model or Type:  RX 60 Robot Integrator: EIMO Americas Key Peripheral Supplier (special tooling, machine vision, etc.): Spectra Technologies Total Robots Installed:  12 Date Installed:  June 2002 Shifts Per

June 2003

KUKA Creates System to Remove Securing Bands from Empty Bottle Crates

POSTED: 06/23/2003

Problem: Securing bands which hold crates of empty bottles together during transport back to the filling plant must be cut and removed before the bottles can be washed and refilled. The extent to which this process can be rationalized is shown by a robot functioning as

November 2002

Material Handling On the MoneyReprinted with permission from Robotics World

POSTED: 11/18/2002

The European Single Currency, the Euro, made its debut in January. April 2001 marked the service introduction of a robot production line set up by GAPE-CEMES at Monnaie de Paris (the Paris Mint) for packaging boxes of Euro coins. Quite naturally, Stäubli robots found themselves a

September 2000

Robofrogs: Hopping Robots Built for Mars

POSTED: 09/15/2000

PASADENA, Calif. - The next giant leap for NASA in space may well be a hop. Walking and rolling have, traditionally, dominated how NASA robots - and astronauts - have moved about places like the moon and Mars. But a select class of up-and-coming robots will literally skip over the idea of

January 2000

Robust Changer for Robotic Spot Welding

POSTED: 01/01/2000

Republished with Permission from Automotive Manufacturing & Production magazine - copyright January 2000.  A robotic tool changer from ATI Industrial Automation (Garner, NC) has been launched that is specially designed for transgun resistance welding operations-not only for the performance of the welding tasks, but for facilitating the required maintenance

June 1999

An Automated Cell for Prosthesis Surgeries

POSTED: 06/01/1999

Orto MAQUET, a 1500-employee German company, and leading operating table manufacturer for the last 150 years, innovates with a new automated cell called CASPAR (Computer Assisted Surgical Planning And Robotics): the first and only robotic surgical system for bone and joint surgery. CASPAR is modern technology for joint-replacement surgery, initially focusing

Archive

Surround and Diversion by a Squad of Mobile Robotic Vehicles

POSTED:

Cooperating squads of robotic vehicles may some day be employed for tasks such as fighting forest fires, cleaning up oil spills, delivering and distributing supplies to remote field operations and conducting a variety of military missions. Control and coordination of groups or squads of robots has thus

Rugged Mobile Robotic Test Bed Platform for Military Surveillance and Reconnaissance Missions

POSTED:

In response to the Department of Defense's Joint Program Office for Unmanned Ground Vehicles' request to develop a prototype of a mobile robotic test bed platform for military surveillance and reconnaissance missions, Sandia's Intelligent Systems and Robotics Center (ISRC) developed SARGE (the Surveillance And Reconnaissance Ground Equipment robot). This prototype

Robotic Coating: Robots Improve Productivity at Glasland Industries

POSTED:

Glasland Industries Inc., a manufacturer of fiberglass products, recently converted its chop and gel coating area from manual operations to robotics after the company was awarded a large contract to manufacture the fiberglass housings of ventilation fans for use in hen houses. Aggressive production plans and

Rapid Response Investigation of Robots for Post-Accident Safety Assessment

POSTED:

When conditions are too dangerous for people after mine disasters, robots can go safely where people cannot to locate survivors, check the atmosphere, or assess the condition of the mine. That is the premise of the US Department of Labor's Mine Safety and Health Administration (MSHA); and

KUKA Robot Handles Ingress/Egress Seat Testing

POSTED:

Problem: (Other Application: Ingress/Egress Seat Testing) Lear Corporation is one of the leading suppliers of automotive seats in the industry. The headquarters located in Southfield, Michigan contains the most sophisticated testing equipment for simulating car seat fatigue over an extended period of time. Terry O'Bannon, Lear's Senior Engineer

Yushin Servo Robot Improves Worker Safety

POSTED:

Problem: Productivity and profitability are the benefits most often associated with molding robots, while one of the most important—safety—is sometimes overlooked.  One large, automotive custom molder, however, installed a Yushin servo robot with the specific objective of protecting workers from a hazardous situation.  And while the installation is

Speed Palletizing

POSTED:

Problem: Intensive manual labor required to depalletize bags of seed. Solution: Design of a turnkey system to automated the process of depalletizing various sizes and weights of bags of seed.  With this system the robot lifts up to three bags at a time.  (No one in the industry was moving

Space Saving Material Handling Solution from Robohand

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Stewart Connector, a manufacturer of plastic connectors for the electronics industry, was experiencing a costly increase in set-up times on a material handling application.  New to the company, and as yet unfamiliar with Stewart's CAD software, manufacturing engineer Keith Crawford was dissatisfied with components supplied by his current supplier (Before

Small Part Deburring

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Problem: Intensive manual labor in a high temperature environment required to unload powdered metal parts from a press deburr and load into an oven for hardening. Solution: Design of a turnkey robotic system to automated the load/unload deburring process.  The operator is no longer required in the high temperature environment. 

Sigpack Delta Robot for Packaging at Pepperidge Farm

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The right choice is being made every day by more and more connoisseurs of fine taste throughout the world, when they opt for a superior delicacy from Pepperidge Farm - a division of Campbell Soup, Inc. Pepperidge Farm also made the right choice when deciding to automate

SCARA Robot Equipped with an Integrated Vision System, Special End of Arm Vacuum Tooling and a Conveyor System Automates Packaging

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Problem: A major pharmaceutical company needed a fully automated packaging to load tablets into cavity blister packs. When packaged manually, unacceptably high scrap rates were common because of the tablets’ soft exterior finish. Solution: Engineers at Janssen-Ortho LLC (a Johnson & Johnson Company pharmaceutical partner) in Gurabo, PR designed

Strong but Gentle Robots Used for Handling Bananas

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When working with fruit, gentle handling is essential. Proof that robots have the necessary sensitive touch is provided by a banana ripening facility, where the strong but gentle machines tirelessly handle crates of bananas. These KUKA Long Range palletizing robots are confronted with a special challenge: they also have to

Robots Impact Production at Mennie's Machine Company, Inc.

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Robots Impact Production at Mennie's Machine Company, Inc. At Mennie's Machine, the term 'innovation' is not a buzzword it is business as usual.  The Illinois-based manufacturer of machined castings and forgings now uses robotic automation to meet their customers' stringent demands for speed and quality.   Previously

Robotic System Speeds Aluminum Wheel Handling

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Challenges Provide flexible robotic system to accurately locate and handle cast aluminum wheels that weigh approx. 40-45 lbs. and nominally measure 14", 15", 16", and 17" in diameter, each with up to five widths. Locate wheels to avoid flashing lines during clamping

Robotic Packaging of Lipstick Containers Decreases Downtime

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SMALL ITEM PACKAGING:     A CASE STUDY             GOAL: Decrease downtime and increase productivity on a packaging line. CHALLENGE: Pick small diameter tubes (in this case, lipstick containers) from a conveyor and place them in

FANUC Robotics Dross Removal Case Study

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Problem: Skimming the dross from a zinc metal bath on a 24/7 production schedule with temperatures up to 878 degrees Fahrenheit is hot, dangerous, back-breaking work. This labor-intensive task with its quality and cost implications gives you all the justifications you need for a great robotic application. That

Robots handle the heavy lifting at Owens Corning

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  The Owens Corning production facility in Newark, Ohio was looking for an alternative method to handle rolls of fiberglass insulation, ranging from 10 to 120 pounds. For over 20 years, production personnel manually lifted the product off of a conveyor and onto

Right out of "1001 Nights"

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Right out of "1001 Nights" Robot performs handling of perfumes Company:  KUKA Robotics Corporation Submitted by:  Manuela Schall Contact:  ManualaSchall@kuka-roboter.de Application:  Material Handling The perfume makers at the Swiss company LUZI AG create aromas right out of "1001 Nights". To produce their fragrant concoctions more efficiently, a robotic cell with an

Vertical Injection Molding Industry Turns to Robotics

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Horizontal injection molding machines with automatic unload systems are a common sight.  Walking through the plant floor of any number of custom molding companies will provide a good illustration of gantry systems that unload finished molded product directly from horizontal molding presses.  The term "robotic unloaders" is the common

Plasma Punch Fabrication Center

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Business: Plasma punch fabrication center Application: Loading and unloading of metal sheets to a plasma punch fabrication center The Problem: Manually loading and unloading the tables is very strenuous and labor intensive.  When unloading the table, the production process must be

Pioneer Hi-Bred International Wins 1999 Robots & Vision User Recognition Award for Robotic Palletizing Operation

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Pioneer Hi-Bred International is one of the largest seed producing companies in the world with headquarters in Johnston, Iowa, and research, production and sales organizations in more than 100 countries.  Because Pioneer is an agricultural-based company, most of the production facilities are located

Machine Loading Cell Made More Efficient with Robotic System

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Problem: The customer wanted to match and automate an existing Okuma machining center with a new Okuma twin spindle vertical lathe.  The operations included maching 8 different bearing housings weighing approximately 40 lbs. each.  Some parts required side 'A' and side 'B' machining, which accounted for 15 separate

Linear Motors Power Disk Drive PNP Robot

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Problem: A major disk drive manufacturer needed a robot to load and unload a large vertical array of Servo Track Writers (STW's) plus an input and output shuttle within a Class 100 mini-environment.  With only a few inches of space for mechanism beyond the travel envelope, the robot

Lights Out System Improves High-Production Machining Process

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Problem: An automotive component supplier recently faced special challenges for a new high-production machining process. Cycle times were not unreasonable for manual load/unload; however, to process parts consistently, 24 hours a day, the company determined that automation was the best solution. Solution: Four LR Mate 100s provided by FANUC Robotics

KUKA Long Range Robot Outperforms Layering Palletizer

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Problem: A robot is required to palletize soft packages onto a pallet.  The essential characteristics of this robot, which is used at a beverage manufacturing plant, is an emphasis on flexibility and availability The robot works on two sides, alternately stacking two sizes of soft packages on Europallets.

Increase Production with Machine Tending Cell

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Increase Production with Machine Tending Cell Company: EPSON Factory Automation Robotics Submitted by: John Clark Contact: info@robots.epson.com Industry: Metal cutting Application: Machine tending cell Integrator: None Problem: Customer needed to increase production from 2 to 6 pieces per minute. Secondary objectives were to reduce changeover times and to have  the ability to

High Repeatibility and Short Cycle Times are Key to Successful Vitamin Palletizing Operation

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Problem: BASF has the right formula ready, not only for manufacturing its vitamin A concentrate, but also for automated palletizing. In a single shift, and in a limited space, a six-axis KUKA robot handles sacks filled with vitamins with a cumulative weight of approximately 30 tons. A decisive

'Growing' the A-class in a robot park

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DaimlerChrysler's Mercedes A-class body shop relies on a variety of joining processes. The entire spectrum of welding, bonding and bolt fastening tasks is covered by 330 KUKA robots of a single type. Compactly integrated in the production flow, the robots represent a 'robot park' in which the car body grows

Efficiency Improved in Molding Auto Parts

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Problem: InteSeys Technologies, Inc, molds a wide range of parts for automotive applications as well as others.  InteSeys has been molding large, complex 100-pin connectors for a popular U.S.-made automobile for four years.  Before using a servo robot in this application, two operators were required to load six-

Molding Optically Clear Lenses for Cellular Phones

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Yushin Servo Robots ideal for clean- room applications.  Case sited: molding optically clear lenses for cellular phones.  Problem: InteSeys (Gilbert Arizona), performs multiple, sequential manufacturing processes for a major cellular phone manufacturer.  Digital-readout lenses are molded, with in-mold decoration.  An adhesive foam pad and a lens protector are

Case Palletizing at SICO-MULCO

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  SICO Inc. manufactures and distributes trade, industrial, and specialty paints, varnishes, stains, coatings, caulkings and adhesives to Canada, Mexico, United States and Europe under a variety of brand names.   SICO Inc.’s St-Hubert’s plant in St-Hubert, Quebec, Canada, recently implemented the company’s first robotic palletizing workcell to

Automated Injection Molding Operation

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Problem: Customer builds electronic components for the automotive industry. They had only 30 seconds to unload molded circuit plates from a four cavity mold, inspect each cavity to ensure that no debris was left behind, load a new insert into each cavity and inspect each insert for proper location

Auto Suppliers' Productivity Jumps 125% with Robotic System

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Problem: Challenges that typically prompt manufacturers to automate one or more of their production processes include: aggressive production schedules, quality control issues, employee safety and flexibility, to name a few. These were all relevant issues for Hawthorne Metal Products (Royal Oak, Mich.), a tier one automotive stampings supplier.  Business

A Robot Palletizer for the Sugar and Flour Industry

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Problem: In recent years, strong competition and the need to find new purchasing stimuli for the consumer, has led large distributors to develop new sales outlet shelving concepts. As was the case in the mineral water and soft-drinks sector, solutions have also been developed for 1 kg

A Firm Grip -- Robots Transfer Vehicle Wheels to Chain Conveyor

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The KUKA robots in use at Südrad, a manufacturer of steel disc wheels, not only have a "firm grip" on the wheels produced there; they have also mastered the art of transferring them to a circular conveyor moving at a variable velocity. The crucial requirements for implementation of this application

How Robots are Used in the Composites Industry

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Increasing costs and environmental regulations have forced composites manufacturers to consider robotic automation for the application of fiberglass chop and gel.  As noted in the accompanying case study, robotic automation can be used to apply spray chop and gel to anything from chicken coop fan housings to boats and bathtubs. 

Robotic Coating: Robots Improve Productivity at Glasland Industries

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Glasland Industries Inc., a manufacturer of fiberglass products, recently converted its chop and gel coating area from manual operations to robotics after the company was awarded a large contract to manufacture the fiberglass housings of ventilation fans for use in hen houses. Aggressive production plans and

Fuel CellPowered Mobile Robots

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Sandia National Laboratories' Intelligent Systems and Robotics Center (ISRC) has developed the RATLER™ ("Robotic All Terrain Lunar Exploration Rover") vehicles to fulfill a wide variety of functions. A RATLER™ was originally developed as a prototype vehicle for a lunar exploration mission; however, RATLERs™ are now used for

Flexible Cable Passes the Test with U.S. Navy

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Problem: As the U.S. Navy began modernizing its Trident II submarines, General Dynamics needed a flexible cable similar to those used with industrial robots and related flex cable applications – except that it had to be a fiber optic cable used in speed-of-light data

Yushin Servo Robot Improves Worker Safety

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Problem: Productivity and profitability are the benefits most often associated with molding robots, while one of the most important—safety—is sometimes overlooked.  One large, automotive custom molder, however, installed a Yushin servo robot with the specific objective of protecting workers from a hazardous situation.  And while the installation is

Small Part Deburring

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Problem: Intensive manual labor in a high temperature environment required to unload powdered metal parts from a press deburr and load into an oven for hardening. Solution: Design of a turnkey robotic system to automated the load/unload deburring process.  The operator is no longer required in the high temperature environment. 

Robotic Production Technology Helps Medallion Plastics, Inc. Increase Production by 35% While Reducing Scrap and Improving Trimming Quality

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Challenge Medallion Plastics, Inc., one of the largest custom thermoformers in Indiana, has undergone tremendous growth in size and diversification since the company was founded in 1976.  The company started as a manufacturer of thermoformed products for the recreational vehicle industry and now supplies quality products

Robotic Trimming Cell Increases Throughput & Reduces Scrap on Sharp-Edged Injection Molded Parts

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Problem: Accurately removing the sharp edge of a parting line on an SUV exterior trim component can be a challenging operation, especially when high-volume production is involved.  Moldplas (Windsor, Ontario), a division of AP Plasman, is an injection mold designer and part producer that had the challenge of finding a better

Motoman System Surpasses Cutting Accuracy and Cycle Time Requirements

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 Challenges Achieve 34-second cycle time, making a 7” bottom cut and a 5” top cut on 0.032” galvanized steel parts (body sides) weighing approximately 30 lbs. each.Produce straight, dross-free edge cut with accuracy within ± 0.020” on

Large Part Handling & Deburring

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Problem: Intensive manual labor required to deburr engine crankshaft and provide a way to check for quality of previous operation. Solution: Design of a turnkey system to automated the process of deburring and performing a quality check of previous operation on two crankshaft styles.  The robot is able to manipulate

Kuntz Electroplating Automated Wheel Polishing System

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Problem Statement Kuntz Electroplating Inc. of Kitchener, Ontario is one of the world’s largest independent OEM chrome plating suppliers, producing millions of plated automotive wheels, bumpers and other components annually. Kuntz is a family owned business which has been in operation for over 50 years, employs over 1,000 people at

KUKA Robot Well-Suited to Flexible Motion Sequence in Cutting and Deburring Operation

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Problem: The user, a medium-sized business, works in three shifts throughout the year, producing toboggans and child seats. The company manufactures 70,000 to 80,000 toboggans per season. After plastic parts finish going through the blow molding process, holes are cut in them while they are still hot; after

Innovative Robotic Laser Cutting And Heavy-Part Material Handling Helps A Leading Automotive Supplier Reduce Operating Costs And Increase Production Flexibility

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  UPF, Inc. is a leading supplier of truck and bus frames to the automotive industry.  Based in Flint, Mich., UPF supplies thousands of truck and bus frames to its automotive customers each year.  A key to UPF's success is its ability to deliver small, medium and large batch runs of

Flexible Router Trimming

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Problem: A blow molder company based in South Carolina looked to expand theirt rimming capacity as well as improve the trimming accuracy of their finished products.  In addition, this blow molder wanted to reduce injuries relatedto trimming while increasing productivity and reducing labor and capitalequipment costs. Solution: Robotic Production Technology (RPT) has designed

Factory Five Racing and Robotic Production Technology Team Up to Improve Kit Trimming Quality and Cost

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Challenge Factory Five Racing, Inc. is a kit car company based in Wareham, Mass. that produces affordable Roadster replicas.  For seven years the company hand trimmed the kit panels using router and trim fixtures.  The trimming results varied depending on the person who did the trimming

Robotic Production Technology Helps Medallion Plastics, Inc. Increase Production by 35% While Reducing Scrap and Improving Trimming Quality

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Challenge Medallion Plastics, Inc., one of the largest custom thermoformers in Indiana, has undergone tremendous growth in size and diversification since the company was founded in 1976.  The company started as a manufacturer of thermoformed products for the recreational vehicle industry and now supplies quality products

Robotic Coating: Robots Improve Productivity at Glasland Industries

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Glasland Industries Inc., a manufacturer of fiberglass products, recently converted its chop and gel coating area from manual operations to robotics after the company was awarded a large contract to manufacture the fiberglass housings of ventilation fans for use in hen houses. Aggressive production plans and

Increasing Flexibility & Reducing Costs with Dispensing Robots

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The trend in manufacturing is clearly changing due to the fluctuations in the economy and uncertainty in many markets.  As recently reported in the Wall Street Journal, factories are using smaller, less expensive machines.  Companies are learning to get more output from their capital investment, minimize

Dispensing DNA Genetic Material

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Contact: info@robots.epson.com Industry: Biotechnology Application: Dispensing DNA genetic material Problem: Research Genetics Inc. needed a fully automated system that would increase productivity, meet extremely tight repeatability specifications and achieve high dot placement density. In addition they required a system that could be programmed in C in order to maintain

Rapid Design and Deployment of Special-Purpose Automated Product Inspection Systems

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Sandia's Intelligent Systems and Robotics Center (ISRC) has proven its capability to develop and deploy automated inspection stations. ISRC designers meet with customers to compile a list of requirements, specifications, and hardware and software needs. From those requirements, a cost-effective system is developed to meet their special

Complex Assemblies: Rapid Automated Generation of Correct Assembly Sequences

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Manufacturing companies throughout the world are rapidly changing in order to survive in today's highly competitive market environments. Some examples of coping with changing environments are manufacturing globalization, automated and intelligent manufacturing, virtual manufacturing, and agile manufacturing. The objective of the movement in manufacturing is to improve flexibility, reliability, and

Dispensing DNA Genetic Material

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Problem: Research Genetics Inc. needed a fully automated system that would increase productivity, meet extremely tight repeatability specifications and achieve high dot placement density. In addition they required a system that could be programmed in C in order to maintain conformity with other applications in their

Automating the Demilitarization of Retired Munitions

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The US Army is responsible for coordinating munition demilitarization for all the Services. More than 300,000 tons of rounds are currently in stockpile waiting to be demilled, some dating back to World War II. This amount is increasing by about 70,000 to 100,000 tons per year. Currently,

Automated Disassembly of Explosive Gas Generators

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Many of the thousands of nuclear weapons which are being retired by the United States contain components known as explosive gas generators. After these components are removed from nuclear weapons, they must be demilitarized. Traditionally, demilitarization has been handled by igniting generators at a burning ground, but

Fiber Optics Patch Cords Patch Cords

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Problem: The manual assembly of fiber optic pigtails requires operators to work with super small parts that have sub-micron assembly tolerances. Improper component assembly causes misalignment of the fiber cables which greatly reduces the output capacity of the finished connectors. Traditional first pass yields from

ROPS Welding

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Problem: Need for updated system with enhance reliability for welding of components. Solution: Design of a turnkey robotic welding system with greatly enhanced reliability for welding of ROPS (Roll Over Protection System) supports for crawler type tractors.  The operator is allowed unlimited access to the inactive positioner for loading/unloading, jogging

Precision Welding Robots Rev Up Motorcycle Frame Production

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Challenges Increase manufacturing capacity to 50-60 frames per day. Reduce dependency on a small number of skilled manual welders.

Epson Automated Inspection Cell

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Problem: A Tier 1 automotive supplier needed to prevent the accidental shipment of defective parts to their customers. Traditional methods had operators inspecting parts; separating known good parts from known defective

Controlled Precision -- Robotic Welding with Touch and Arc Sensors

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  When the textile machine manufacturer Trützschler makes rotary drums for high-performance carding machines, extremely high precision is demanded. Although the drums are made of solid steel plates, once they have been turned and ground they must meet extremely tight tolerances at high rotational speeds. This level of precision is made


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