Check the pick&place application working in tandem with a pneumatic-hydraulic press
Robotised workplace with aluminium flange forming presses
The task was defined as follows – at the input, the machine must be equipped with a container to be periodically filled with semi-finished product, the aluminium flanges are to be oriented correctly and subjected to two-stage pressing. At the output, a vision control system must confirm the compatibility of the product with the permissible norms and, in case the workpiece fails to meet the norms, it should be rejected.
In the design, given that the work cycle of the machine set at1 ready workpiece / 3.5 sec., we decided to use two presses equipped with pneumatic-hydraulic actuators with a 2-stage stroke, i.e.fast pneumatic infeed and working feed with the nominal force of 80kN. At the centre of the machine, in between the presses, a SCARA-type robot was installed.
Thus, we achieved a several-fold increase of efficiency in comparison to the original workplace with a traditional hydraulic press operated manually. Also, work safety improved significantly as a result of replacing the machine operator with a robot and separating the work area with monitored screens.
The task was defined as follows – at the input, the machine must be equipped with a container to be periodically filled with semi-finished product, the aluminium flanges are to be oriented correctly and subjected to two-stage pressing. At the output, a vision control system must confirm the compatibility of the product with the permissible norms and, in case the workpiece fails to meet the norms, it should be rejected.
In the design, given that the work cycle of the machine set at1 ready workpiece / 3.5 sec., we decided to use two presses equipped with pneumatic-hydraulic actuators with a 2-stage stroke, i.e.fast pneumatic infeed and working feed with the nominal force of 80kN. At the centre of the machine, in between the presses, a SCARA-type robot was installed.
Thus, we achieved a several-fold increase of efficiency in comparison to the original workplace with a traditional hydraulic press operated manually. Also, work safety improved significantly as a result of replacing the machine operator with a robot and separating the work area with monitored screens.
Our commentary
“A project that hit the bull’s eye for the Client and gave us two subsequent implementations, including one in the US branch.”
Błażej KempińskiInlader, project manager
Project implementation pictures
The visual monitoring system verifies the workpiece diameter; an additional precise height measurement compensates for the “perspective” effect of the vision sensor
The SCARA robot in the course of the pick&place task
The press is based on a cylinder in which both the pneumatic component and the hydraulic component are arranged within a single compact housing; the press does not require an additional oil circuit
Machine operation includes only filling the container with semi-finished product
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C&I Design
C&I Design
Electrical switchboards and automation cabinets
Systems:
– power supply and distribution
– control
– drive
– pneumatic
– measurement
– positioning
– safety
Areas:
– process automation
– machine automation
– robotics
E-Plan P8 software
Concept
Concept
We offer consultations in the course of which, accompanied by our Client, we analyse the assumptions of the project and based on a detailed survey we work out the investment budget.
We render services relating to the preparation of a comprehensive concept of the system. That includes the following:
– Specification of products, packaging type and pallet templates
– Efficiency analysis
– System operation algorithm
– 2D scheme
– 3D scheme
– Electric and pneumatic installation plans
– Power balance
– Component list
– List of collisions
– Work schedule
3D Design
3D Design
We design system layouts, integration with production processes and unit machines, such as: transports, turntables, stackers, pallet storages and robot grippers.
In the process of 3D designing, our engineers use Solidworks. In order to manage changes to the working plans and specifications, we use Solidworks PDM.
Control
Control
We devise applications for articulated robots, Delta, SCARA, as well as cooperating robots. We use 3D models to conduct simulations prior to starting production. At this stage, we can verify the required ranges and cycle times.
In addition to robots, we deliver comprehensive PLC software for operation and integration with the production process, as well as SCADA and HMI for visualisation.
Production
Production
A robotised process is a modular system. We buy some elements of the system (robots, wrappers, labelling machines) from our suppliers.
The list below includes the components manufactured by us and delivered in accordance with the contracted delivery schedule:
– Transport systems
– Cross transfers
– Turntable transfers
– Pickpoints
– Stackers
– Pallet storages
– Grippers
The production process involves the approval of the design, order for the production of prefabricated elements, machine assembly and workshop testing.
Commissioning
Commissioning
The system is implemented at the Client’s site under the supervision of the project manager.
Stage 1 includes mechanical assembly of the machines delivered, followed by pneumatic and electrical installations and, finally, software activation, in the course of which our engineers carry out the start-up test, production tests, optimisation as well as training for system operators and maintenance technicians.
Service
Service
We care for the safety of our application, both during and upon the expiry of the contractual warranty period
We offer a range of standard options as well as paid extended packages.
The differences concern the following: – Terms and conditions of delivery of service requests
– Service reaction times
– Availability of standard spare parts
– List of critical components
– Terms and conditions of remote VPN connection
– Terms and conditions of remote video monitoring
Control systems
Control systems
PLC drivers for process and machine applications
DCS systems for big technological applications
Safety systems for automation and robotics
Vision monitoring systems for inspection, colour recognition, failure detection and object identification
Total quality control: the cabinets are produced in our shop, by our installers and under the supervision of our designers.
Production process: – Acceptance of documentation
– Verification of submitted materials
– Distribution of elements
– Making holes in the housing
– Mechanical assembly
– Labelling of components
– Wiring
– Technical inspection
– Photographic documentation
– Packaging
Our standards also encompass production assortment, manner of installation, as well labelling technology.
We perform electrical, pneumatic and teletechnical installations.
We know the hygiene standards (HACCP).
We have our own, detailed guidelines for every type of the installation
We inspect electrical cabinets with the use of a thermal vision camera.
Commissioning process: – I/O tests
– tests with no product
– tests with the product
– production optimisation
– training for technicians and operators
– assistance
Service
Service
Quick contact with the service team:
– serwis@inlader.pl
– +48 574 220 422
We ensure the safety of our applications both in the guarantee and post-guarantee term.
For years, we have successfully used the VPN connection in order to intervene or diagnose the source of the failure remotely.
We also use remote video monitoring.
Production
Production
A robotised process is a modular system. We buy some elements of the system (robots, wrappers, labelling machines) from our suppliers.
The list below includes the components manufactured by us and delivered in accordance with the contracted delivery schedule:
– Transport systems
– Cross transfers
– Turntable transfers
– Pickpoints
– Stackers
– Pallet storages
– Grippers
The production process involves the approval of the design, order for the production of prefabricated elements, machine assembly and workshop testing.
Commissioning
Commissioning
The system is implemented at the Client’s site under the supervision of the project manager.
Stage 1 includes mechanical assembly of the machines delivered, followed by pneumatic and electrical installations and, finally, software activation, in the course of which our engineers carry out the start-up test, production tests, optimisation as well as training for system operators and maintenance technicians.
Service
Service
We care for the safety of our application, both during and upon the expiry of the contractual warranty period
We offer a range of standard options as well as paid extended packages.
The differences concern the following: – Terms and conditions of delivery of service requests
– Service reaction times
– Availability of standard spare parts
– List of critical components
– Terms and conditions of remote VPN connection
– Terms and conditions of remote video monitoring
Student trainee – constructor
Student trainee – constructor
Participation in:
machine / construction design at various stages of progress (concept, 3D model, 2D documentation)
supervision of assembly works
machine functional testing
Requirements:
university degree in technology, major: mechanics and machine construction, mechatronics or automatics and robotics (or in the course of studying)
good command of programming of CAD 3D (Solidworks, Inventor)
knowledge in the field of mechanics, and pneumatics
creativity and conscientiousness
teamwork skills
command of English
readiness to work in various locations at home and abroad
Student trainee – designer
Student trainee – designer
Participation in:
design and preparation of C&I technical documentation
design and implementation of new solutions for production purposes
introduction of changes and modification of existing projects
Requirements:
university degree in technology, major: automatics, robotics, electrical engineering, electronics (or in the course of studying)
basic command of CAD
creativity and conscientiousness
teamwork skills
command of English
readiness to work in various locations at home and abroad
Student trainee – programmer
Student trainee – programmer
Participation in:
development of control algorithms
creation and implementation of applications
creation and implementation of visualisation applications and reporting systems
Requirements:
university degree in technology, major: automatics, robotics, electrical engineering, electronics (or in the course of studying)
basic command of PLC industrial driver software
basic command of SCADA and HMI
basic knowledge of issues relating to databases
creativity and conscientiousness
teamwork skills
command of English
readiness to work in various locations at home and abroad
