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THE IMPORTANCE OF SUPPLY CHAINS

The acquisition of reasonably priced materials can make or break a company. In our modern world, industries and consumers are expecting goods to be delivered faster and cheaper than ever seen before. Industries must also ensure sufficient product is being delivered or created to match demand or run the risk of empty or leftover inventory. Meeting these constraints is highly dependant on the effectiveness of a company’s supply chain.

What is a Supply Chain?

In simple terms, a supply chain is the activities required by organizations in order to acquire and/or deliver goods. These activities usually include the transformation of raw materials into an end product for a customer, and the transportation in-between. Without an effective supply chain, a company runs the risk of reducing customers or losing an advantage over other competitors.

chain supply

Important Aspects

Supply chains are an essential part of the business structure and drive the economy. Understanding the following key aspects of what a supply chain is and how it operates is crucial for any business.

Diversity

Not all supply chains are operated by the same organization. In fact, the majority of supply chains involve many parties with different corporate interests. Therefore, companies may not be aware of other participants within the supply chain.

For example, a raw resource company that extracts iron ore and refines it to steel may sell it to an industry that makes robotics parts and electronics overseas. From there, the robot manufacturer would produce and assemble the robots to sell as full robotic cell assemblies to another industry that would use the robots on an assembly line (and the supply chain would continue from there). The ore refining company would have no insight on the business to which the robotic cell industry sold since it is on the other end of the supply chain. However, both are dependant on each other. If either company were to remove itself from the supply network (by going out of business or leaving the trade network), both companies would suffer.

That being said, any company would ideally seek to maximize its profits. If a company was to increase the price of its materials at the beginning of the supply chain, it would ultimately affect all other participating companies down the line, leaving the company or consumer at the end with an excessive cost. This could result in the ‘end’ company or consumer seeking another supplier and therefore disrupting the current supply chain. Organizations must work in cohesion by offering fair prices in order to construct an effective supply chain and not lose consumers. Doing so will increase the profitability of all organizations involved.

Supply & Demand

In order to maintain a steady supply chain, resources must be frequently available. When prices go up, delays become long, and when it is hard to get the required resources, industries will be unable to meet orders or schedules by their consumers. This will disrupt all players further down the supply chain and can greatly affect profitability since customers will look elsewhere to receive their goods. It is a smart strategy to have a plan to find another supplier before the previous is unable to provide the required recourses.

Chain supply

Despite the several layers of companies involved within a supply chain, it only operates effectively if there is customer behavior at the end of the chain (customer demand). Supply chain processes should be co-ordinated to focus on a customer’s needs. If no customers are purchasing goods from an ‘end’ company, the supplier will see fewer profits due to decreased demand, and vice versa.

Unexpected Events

Being the main contributor to supply chain disruption, unexpected events should be properly prepared for. These events can be classified into two categories: internal and external. Internal events usually entail anything which the supply chain companies are responsible for. This involves things like product recalls, transportation disasters, cost escalation, etc. External events involve occurrences that aren’t controlled by the supply chain company like border restrictions, natural disasters, importing taxes, etc.

For example, in recent events from the COVID-19 pandemic, many supply chains have been disrupted or halted due to the closing of borders and increased importing protocols. The global economy was greatly affected by the shutdown of businesses and we are still recovering. This is a prime example of an external unexpected event: a global pathogen.

In both cases of unexpected events (and decreased supply), keeping an inventory can prove quite useful. By having an excess of materials or products, any company which is experiencing slowdowns due to unexpected events can still fulfill its procedures. In severe terms, an inventory can also give a company enough time to find another material supplier. Many retail and industrial businesses own and manage storage facilities (warehouses) for these scenarios if they arise.

In the case where products can not be delivered or when the prices of the products go up, exploring a second-hand market is always an option. This gives the consumer company time to create a complete order when the delivering company fails to meet expectations. For example, a car manufacturing company that ordered a number of industrial robots only received a fraction. In order to stay on schedule, second-hand robots may need to be purchased. By knowing your supply chains, scoping out when second-hand purchasing is needed will be an easy task.

Chain supply

Conclusion

Therefore, performing due diligence with the supply of resources, internal/external events, company diversity, and the demand within or affecting the supply chain will allow for it to perform smoothly. That concludes this week’s post, if you have any questions about supply chains and their meaningfulness within an industry or if you have any other questions, please feel free to visit our contact page: https://diy-robotics.com/contact/

References

  • Coupa. “5 Scary External Factors for Supply Chains.” Coupa, 31 Oct. 2020, https://www.coupa.com/blog/supply-chain/5-scary-external-factors-for-supply-chains
  • “What Is Supply Chain Management and Why Is It Important?” Indeed Career Guide, https://www.indeed.com/career-advice/career-development/what-is-supply-chain-management-and-why-is-it-important.

OPTIMIZED FACTORY SHUTDOWNS

In order to be on track with today’s fast-paced, technology-driven world, industries have begun integrating automated processes to their production floors for a more efficient way of manufacturing goods. Robotic installations are a prime example of a crucial technology needed in present-day manufacturing. When performed correctly, robotic integration has many benefits. However, there are precautions that must be taken in order to ensure the technologies are installed swiftly and correctly. Often, robotic integrators are forced to shutdown equipment, or entire production floors in order to achieve this. This is referred to as Factory Shutdowns.

What is a Factory Shutdown?

As the name implies, a Factory Shutdown is a temporary closure of a production building to perform maintenance. Usually, these shutdowns are done to perform equipment inspections or deal with unplanned downtime. They are also performed to allow the integration of new equipment or technologies. Time, effort, and money devoted to shutdowns can sometimes be underestimated. This is due to the fact that elaborate planning and executions are required. Integrators may be unaware of certain layouts on a machine floor and will need equipment to be relocated to install their technologies properly. Or perhaps a software component within the machines (new and old) must be compatible in order to operate as one. Processes such as these are lengthy and costly, the company or the integrator must ensure every aspect of the integration process is planned and executed correctly to not waste possible production time, and in turn, reduce profits.

How DIY Robotic Cells can Help

How to Avoid or Reduce Shutdowns

Due to the nature of shutdowns and how they reduce profitability, companies should try to reduce the time spent in shutdown, or eliminate them entirely. Below are a few solutions to optimizing factory shutdowns due to robotic installations:

  • Develop a strategy in advance on how to accomplish integration. This includes assigning job tasks, resource planning (people, materials, tools), risk and safety assessments. This ensures that if any aspect of the integration process is delayed, there is a concrete plan set in place to put it back on track.
  • Schedule enough time in the case that issues arise. No matter how detailed a project plan is, unplanned work is inevitable. Not accounting for this work can have a huge impact on a budget or timeline. A time threshold should be set in place to ensure unseen issues do not ruin a project.
  • Employ an integrator with a time-efficient process to installation. This could involve prebuilding equipment that can be installed with ease, rather than supplying a company with only the parts.
  • Employ an integrator that offers a turnkey solution. Since all phases of integration are consolidated under one company, tasks are easier to plan, communication errors are less likely to occur, and any errors in integration are left to the experts. This will save a tremendous amount of time, for both parties.
  • If there are multiple production devices available, integration of the new technologies could take place on one of the devices while the others are still operating. This ensures the product is still being created while upgrading the upgrade is taking place. If there is an error with integration, only one machine would be affected.

How DIY Robotic Cells can Help

Factory shutdowns are a lengthy process. Companies should find a robotic integrator that can install technologies effectively, while still optimizing installation time. DIY Robotics provides the necessary solution to optimizing shutdown time. All DIY Robotics products come pre-built which reduces installation time greatly. Our cells are also modulare, which means they can be moved or altered with ease. Many robotic installations are bolted to the ground and therefore are fixed in position. These robots take unnecessary time to install or maintain (adjustments). By choosing DIY Robotics products, installation or maintenance can be easily executed due to its modulare capability. DIY Robotics also offers its products in turnkey solutions through a panel of official integrators familiar with the product. Integration/Customization of our machines can also be made at our facilities. All unexpected errors would be addressed before delivery, and any unique customizations would also be established. This could involve certain cell layouts, adjustments on the robot, custom EOATs, etc. Therefore, it would only take a few days to make a production line operational.

What is a Factory Shutdown?

All of these benefits listed above can help reduce shutdown time tremendously. A shutdown timespan of 2-4 weeks could easily be reduced down to 2-4 days with our products. If you are interested in learning more about our robotic cells, or have a question regarding other technical material, please feel free to visit our products page or contact us.

References

WHAT TO KNOW ABOUT ROBOTIC CUTTING INSTALLATIONS – Punch & Die, and Routers

Automation has become one of the essential building blocks for any manufacturing company. It saves money and helps eliminate hazards within the workspace. One of the most common practices which should incorporate automation is cutting installations. Automated cutting installations provide a high accuracy, cost–effective way to cut and shape materials without subjecting workers to dangerous components. 

In this post, the final topics of our series on robotic cutting installations will be addressed: Punch & Die, and Routers. In previous posts, we touched on the other two applications, Laser Cutting and Ultrasonic Blades. If you are interested in either of these topics, you can find the content located at these links: 

Laser Cutting here

Ultrasonic Blades here

Punch & Die

Punch and Die (also known as Punching) is a cutting process that forces a tool (the punch) through a workpiece to create a hole or cut via a sheer load. A die is located on the opposite side of the workpiece to support the material around the perimeter of the hole profile. This is to ensure a clean cut is made and all forces are correctly directed to avoid deformations. Clearance between the punch and die is needed to prevent the punch from impacting the die. This clearance is dependant on the hardness and thickness of the material, and the type of profile desired. 

Punch and Dies are often made of hardened steel, or a material tougher than that of the cutting material. Punch and Dies are most commonly used to cut metals and plastics. This equipment is usually mechanically operated since a very large load may be required to cut certain metals. However, simple punches can also be hand-powered. Punching is often the cheapest method for creating holes and cuts due to its simple process. Leftover material can also be recycled to create more products (whereas routers grind away reusable material). Punching is used in high production settings where it can cut at an efficient rate and is extremely accurate. 

Punching is usually seen in metal cutting industries where parts are produced at a large rate. Automotive manufactures must produce various parts for their vehicles, and the Punch and Die is a common method used to do so. 

Safety

The amount of force required to pierce the material between the Punch and Die is quite substantial and therefore dangerous. This machinery could easily separate flesh and bone and should be averted from human contact. By installing a robotic cell, it would eliminate any chance of a human coming in contact with an operating punch an die while still keeping an efficient production rate. 

Routers

A Router is a grinding tool that uses a motor and a specifically designed cutting bit. This bit spins at an extremely high speed which (depending on its type) can cut through wood, plastics, aluminium, and most metals. Various shapes and profiles for bits are available to allow for customed grinding. Basic routers can be seen in woodworking and are usually handheld or affixed to a table. Industrial routers, however, are usually automated through the use of a robot since they are capable of accurately following a specific path and/or geometry. 

Unlike the other cutting methods discussed in past blogs, routers possess the ability to cut, shape, and carve materials in 3D (rather than 2D surfaces). Although ultrasonic blades can be used in 3D shaping, they are not as accurate or efficient as routers. Specific depths and contours of a material can be met through the use of routers which may be essential to certain manufactures (i.e. Automotive parts). Routers can be incorporated with CNC machines to allow for an efficient 3-axis way to create 3D parts. 

Safety

The bits that routers are equipped with have the capability to grind away hard materials and therefore would be a risk if humans interacted with it directly. Like any cutting application, it would be ideal to have protective barriers limiting human contact with hazardous devices. Robotics cells provide the necessary safety precautions for this cutting application. 

Conclusion

That concludes this three-part series on robotic cutting installations. Each topic has gone into detail about their advantages, process, and safety. If you missed the other two topics on cutting installations, or perhaps you are interested in other technical topics, please feel free to visit our blog page: https://diy-robotics.com/blog/. If you have any questions or concerns regarding this topic or would like some insight to our products, please feel free to Contact Us. Stay connected with DIY Robotics for more technical posts in the near future. 

References

SELECTING THE RIGHT INTEGRATOR FOR AN AUTOMATION PROJECT

As technologies advance, new processes in manufacturing present themselves all the time. These processes can save time and money, boost production efficiency, and create more market opportunities. However, most manufacturers need the assistance of an outside integrator to establish these technologies, since they are not familiar with the new systems. Finding and selecting the right integrator that suits all business needs is not an easy task. The right integrator should understand a company’s situation and goals, and develop a plan to execute them. In this article, we will address some key points when selecting an integrator, and how they are essential to achieve an organization’s vision.

The Five Key Details

Field of Work

When selecting an integrator, the first action should be to ensure that their field of work matches what technologies you want to implement. Does the selected integrator deal with the appropriate products to achieve a company’s vison? Let’s say a company was working with a computer software integrator that mainly deals with IT systems, when the desire is to implement an automated labeller into a machine floor. This situation would not be ideal for both parties. The company should have been working with an automation integrator.

Expertise & Experience

It is crucial for an integrator to have the required credentials, expertise, and experience in the field they work with. If their expertise matches your goals, you have found the right integrator. If they specialize in a specific technology which is not useful for your company, they might not have enough general knowledge for your specified solution. If the chosen integrator shares a brand or company with the equipment your company already possesses, this integrator may be the best choice (due to it direct specialization).

As for experience, there may be projects or research that an integrator has conducted which correlates with your company’s interests. It is also important to know if an integrator has had previous successful business operations. If an integrator provided poor service, or did not meet expectations, it would not be ideal for another company to work with them in the future.

Knowledge

Methodology & Maintenance

An integrator should have a direct approach when implementing their systems in any workspace. This could involve delivery promises, risk analysis, and overall timespan. Effective planning is key, and an integrator needs to ensure they do not use up much of their consumer’s time. Time spent installing the integrator’s technologies could be time spent making money.

Offering a maintenance system to their products is also an important aspect which should be available with an integrator. If any errors should arise from using an integrator’s product, a company should assume that the integrator possesses the necessary solution to stop the problem. This way it puts the experts in control which saves time and stops unnecessary troubleshooting if a company were to do it themselves.

Compatibility

Compatibility between an integrator and an organization is essential. Both parties (being business partners) should be on the same page with regards to implementing the technologies effectively. The integrator should ensure all goals of the organization are being met, provide ongoing support through installation, and keep time and cash- usage low. Expenses are an organization’s biggest fear. Although an integrator may have exceptional expertise and product quality, the overall cost may be a deciding factor. It would also be ideal for an integrator to utilize technical terms the organization is accustomed to. This could involve programs or computer languages of their customer’s equipment. This is to ensure complete understanding when initiating the consumer to the new technology, and therefore gives them the best experience.

Compatibility

Knowledge Transfer

Training on how to operate the equipment should be common practice with any integrator. An organization deserves to know how equipment is operating within their workspaces. All knowledge of the product should be available to the organization for review. This could range from technical booklets, operation instructions, troubleshooting tips, etc. By acquiring crucial knowledge from the integrator, organizations reduce the risk of downtime with the newly installed systems and keep a strong relationship between both parties.

Conclusion

An organization’s success greatly depends on the integrator chosen. There are several factors (as stated above) that should be taken into account during the selection process. Taking the time to research various integrators and their expertise, methodology, and compatibility will be well worth it in the end.

At DIY Robotics, we offer turnkey and DIY solutions while still keeping a low cost with our ‘plug-&-play’ products. Free support is available for all organizations who select our products. We offer the development of your internal resources by supplying technical documents and training programs. We also make the selection of a robotic cell integrator an easy task with our panel of official integrators (for turnkey solutions). At DIY Robotics, we value our customer’s experience above all else. If you have any questions regarding our products, list of integrators, or topics addressed in this post, please feel free to reach out on our website: https://diy-robotics.com/contact/

References

  • McCarthy, Matt. “Automation Solutions: How to Choose the Right System Integrator for You!” Intec Automation, Inc., Intec Automation, Inc., 7 Oct. 2021, https://www.intecautomation.com/automation-solutions-how-to-choose-the-right-system-integrator-for-you/.
  • “Turnkey Industrial Robotic Solutions – DIY-Robotics.” DIY, 22 Nov. 2021, https://diy-robotics.com/turnkey-solutions/.

WHAT TO KNOW ABOUT ROBOTIC CUTTING INSTALLATIONS – Ultrasonic Blades

Robotic cutting is an automated process of shaping or removing material. This process is high in accuracy, speed efficient, and quite cost-effective. This is why industries have been evolving their workplaces to involve these robots and their applications. It provides the necessary criteria to increase overall efficiency and helps eliminate any hazards workers are subject to when near cutting installations.

Automated cutting comes in many different forms. These include but are not limited to Laser Cutters, Ultrasonic Blades, Punch and Die, and Routers. In a previous post, we talked about Laser Cutting and its applications. If you are interested in the information supplied there, please visit the web page here.

In this post, we will be covering Ultrasonic Blades and their applications, and touch on the remaining topics (Punch and Die, Routers) in a later post.

Ultrasonic Blades

First developed in the 1950s with drills, ultrasonic technology has a wide range of applications and is routinely used in industry. Due to their accurate cutting capabilities, robots are often equipped with them to ensure the cleanest cuts out of selected materials. Ultrasonic cutting is commonly used with textiles and food products and can even be seen in medical practices with bone surgery. As for the industrial side, many factories which incorporate ultrasonic blades into their production procedures will cut plastics, rubbers, and foam (since they are often produced in bulk).

cutting bladeUltrasonic Blades rely on ultrasonic vibrations to allow them to cut various materials. Ultrasonic Blades vibrate around 20 – 40 kHz (20000 – 40000 times per second), which can easily cut through the materials stated above. This blade vibrates so fast that the material between each stroke is minuscule compared to that of the blade size. Therefore, cuts are often cleaner and more accurate with minimal debris compared to other cutting applications. Depending on the thickness of the material or speed constraints a higher frequency may be required.

The cutting blade has what is called a natural frequency. By adding external forces that correspond to the blade’s natural frequency, a large oscillation is achieved. This is known as resonance. Throughout its operation, the ultrasonic blade uses what is called the Piezoelectric effect or Magnetostriction to maintain this resonance.

human safetyAlthough the ultrasonic blade is not recommended to cut metals, it makes up for it by being one of the most accurate ways to cut. Material lost during the separation process is also reduced compared to other cutting methods. Laser cutters burn away unwanted material, and Routers carve it to dust. This saved material from the ultrasonic cutter could be recycled to create more products and therefore reduce costs. The ultrasonic blade also removes any chance of the cutting material being ignited. Laser cutters present that danger due to the high-temperature laser and routers from the friction of griding. Ultrasonic cutters are generally quite cheap compared to other cutting methods, and the blades are easily replaceable.

As for the ultrasonic blade disadvantages, is not as efficient as laser cutters or routers when it comes to engraving or carving designs. The ultrasonic blade is meant for separating materials, not shaping them. This cutting method is also limited to softer materials like plastics, rubbers, and foams.

Safety

Like any cutting application, all personnel should ensure they are a reasonable distance away from the machinery to avoid injury; but that should be standard practice when dealing with any robotic automation. Ultrasonic blades have the ability to cut through flesh and therefore should have some protective barriers to avoid human contact.

Integration of a robotic cell would be ideal to increase the safety of this technology. Not only do robotic cells allow full operating capacity, but they also restrict human contact. DIY Robotics offers a wide range of Modular Robotic Cells, which allow for a safe mechanical workspace. The modularity of these cells allows for full flexibility when any changes or layouts are required by the user. If you would like more information regarding our Modular Robotic Cells, please feel free to visit our website.

That concludes the content for Ultrasonic Blades. Please stay connected for the final in the following weeks: “What to know about robotic cutting installations – part 3” where we will touch on Punch and Die, and Routers. If you are interested in the topic discussed or have any questions regarding the material, please feel free to contact us. We shall put you in touch with one of our experts.

References

Understanding Dispensing Robots

Dispensing is one of the many tasks that a robot can do. There are several aspects that need to be understood before selecting a good dispensing robot. Let’s go through them to try to make things clear.

What is it? How does it work?

As the name suggests, a dispensing robot is any robot that dispenses a variety of items such as adhesives or paint. Other than dispensing materials, it also sometimes sorts and counts items, transfer parts or fills up tanks.

Their most important characteristic is that they are leak and ejection-proof. The nozzle end opens up to pour or dispense a specific predefined quantity of material or fluid at a specified location. It then closes. They use methods like precise shutoff and “suck back” to reduce the wastage of fluids via diaphragmatic valves and motors.

Types and applications

There are various types of dispensing robots available on the market adapted to all sorts of requirements. These types are defined by the kind of material they are dispensing, the needed speed and accuracy, which number of axes are required, and also which industry the robot will be used in. In light of that, two broad categories emerge One to three-axis robots and four to six-axis robots. Let’s look at them in-depth:

One to three axis: These robots are only capable of linear motion, and lack rotational movements because they are limited between one to three axis. This being said, thanks to their limited movement, they can operate with high speed and accuracy. One example of this is a benchtop robot. One axis is controlled by the bench and the other by the Cartesian robot mounted on top. Similarly, SCARA are also in this category with (3-4 axis) variants. A classic example of this robot type is the toothpaste filling robots in the consumer goods industry.

Four to six-axis robots: Capable of moving in multiplanes, four to six-axis robots are also called robotic arms. They have joints that enable linear movements but also rotational movements. This allows these dispensing robots to work on angular planes, multiplanes, and dispense fluid in a rotational motion. A classic example of this kind of robot is the paint robots used in the automotive sector. Applications range is:

  • Electronics
  • Plastic parts in plastic industry
  • Automotive
  • Aerospace
  • Pharmaceutical
  • Paint dispensing
  • Wax seals
  • Adhesives

Benefits

Among the many benefits of automated dispensing, the increase in throughput and assurance quality of the product and process, for manufacturers, is really quite cost-effective in the long run. To list a few more benefits, dispensing robots:

  • Increase throughput
  • Increase process reliability and repeatability
  • Reduce unwanted dispensing
  • Reduce manufacturing time
  • Guaranty accuracy, irrespective of dispensing surface
  • Increase the ROI
  • Remove safety issues in manual dispensing
  • Reduce manufacturing costs

Choose the best fit

The selection process of the proper dispensing robot is an important aspect when aiming to obtain full benefits. The following factors should be taken into consideration to insure the selection of the proper dispensing robot:

  • Dispensing methodology
  • Dimensions of the robot
  • Size of the part or fluids
  • Material loading
  • Robot speed
  • Number of axes required
  • Dispensing path and movement in axis
  • Add-on capabilities to work across production lines

One of the most important things to remember when choosing any robot is that they are not supposed to replace the human workforce but rather increase the efficiency, reliability and throughput of that workforce’s production line. Automation in dispensing robots allows this operation to run around the clock. This solution is certainly not perfect, but the benefits are considerable. Once all the conditions to choose the correct robot are met and the right path is selected, a manufacturer will see a visible difference in their output.

Contact us for more information about our robotic cells that could fill up a dispensing task.

Industrial Robotic Cell - DIY-Robotics

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References

  • Roboworx, “Dispensing Robots,” 19 08 2021.
  • Assembly, “Implementing Dispensing Robots,” 06 12 2005.
  • M. building, “Considerations when choosing a dispensing robot,” 11 08 2020.

More about HEAT STAKING:

When assembling a part, some of the most important components to consider are the connections and joints. If the joints are weak, the whole structure will be weak. Heat Staking is the process of melting a boss from a plastic component into the hole of another component. The heating process can be accomplished using different ways such as hot air, ultrasonic system, or contact heating element.

Heat_Staking_process

Of the aforementioned options, heat staking is the one this article is dedicated to. It is a type of staking used in the plastics industry. Let’s dig a little deeper into that process to learn what it is and what is it used for.

Heat Staking:

The type of staking that involves melting a piece of plastic to hold two parts together in an assembly is called heat staking. During this process, the plastic boss is heated to a temperature where the boss melts and pressure is applied, then the boss is cooled down to form the bond. This process is low in cost compared to welding and other joint-making techniques. It can also be used in various industries because it offers the possibility of working on huge volumes in a cost-efficient manner.

Staking is a good solution to avoid vibrations and stress cracks. It can also be a way to avoid using additional hardware to prevent possible quality control issues due to defects. Even more so than other methods, it benefits manufacturers because the whole process of combining materials is finished in a single cycle time. This process uses the same base material throughout, has more pull strength, and doesn’t cause any mechanical stress. There are various methods of heat staking. To only name a few: hot tool staking, hot air staking, ultrasonic, and focused infrared energy.

The process of heat staking is used for various applications. It ranges from joining automobile panels to medical equipment to packaging, and more. In this blog post, we will turn the spotlight on two innovative heat Staking methods designed by Extol. The InfraStake and the Nanostake are, as mentioned, innovative technologies with the ability to stake in tight and delicate spaces.

The InfraStake

For this patent technology of heat staking, instead of a heating tip, infrared light is used to generate the heat. The InfraStake module is placed over the boss and its opening clamps the part to be staked. A concentrator is used to concentrate the heat only on the staking part. The IR bulb heats the boss radially and a punch performs a stake on the heated boss. To cool the part, airflow passes through the Infrastake module and then the punch retracts.

Robotic_Heat_staking_Cell_With_InfraStake

Here are a few benefits of InfraStake:

  • Safe for fragile components
  • Sturdy
  • High accuracy and repeatability
  • No smoke generation
  • High quality
  • High pull strength
  • Reduces stress joints
  • No surface damage
  • Mobile and modular
  • Low energy consumption
  • Changeable punch as per the requirements
  • Can be used in congested areas

The NanoSTAKE

This heat staking method is famous for its instant cooling effect. The staking rod cools down within a few seconds. This smart respond heating technology is also patented by Extol. The heating temperatures are regulated using low current value and increased efficiency. The current used is as low as 1.5A, making it easy for any connection.

The various benefits of this process are:

  • No plastic will get stuck
  • Can be used in congested areas
  • Easy connectivity
  • Low current-High performance
  • Comes with a LED indicator for real-time module status
  • The module remains cool even when the boss is heated

At DIY Robotics, we are collaborating with Extol and making a Robotic Heat staking Cell bundle, using the InfraStake technology. There are three models of InfraStake options depending on their stake dimensions: IS32, IS125, or ISM20.

Among the many heat staking and plastic staking technologies on the market, choosing the appropriate technology that can best serve your needs is quite a process. There are various factors that manufacturers need to consider before finalizing their choice. This is especially true when manufacturers want to adjust the staking process to their existing setup in order to save time and money. Manufacturers need to invest in the upcoming and latest technology that offers a short setup and installation time, high-quality machinery, and a quick ROI. One such solution is the DIY Robotics Heat Staking Cell with the Extol InfraStake heat staking module. Have a look at this new bundle and learn more about the InfraStake Technology.

Industrial Robotic Cell - DIY-Robotics

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References

Why a Packaging robot?

“Packaging can be a theater, it can create a story.”  ̶  STEVE JOBS

According to an Allied Market Research report, the global market for packaging robots is set to reach $4,649 million by 2023. Clearly, packaging is an important aspect of the manufacturing industry. Apart from protecting the product, packaging also improves the marketing of the product itself and its company.

Automated packaging installationsAutomated packaging installations not only provide quick ROI when deployed, but they also bring speed, accuracy and productivity to the production line. Let’s get into what packaging robots really are.

As the name suggests, packaging robots are used to palletize, carton and case products. Packaging can also include various other aspects like labelling, sealing or filling.

These robots mimic human hand movements to pack products. This allows them to pick, move, seal, label and pack. Different end of arm toolings can be added to the robot to best fit the product requirement. Articulated and delta robots are commonly used for packaging due to their degree of motion.

Benefits

Automated packaging installations give industries a huge boost in their productivity by reducing the time spent on this task. In the long run, this makes them far more cost-effective than manual labor.

Packaging robots are also quick between tooling changeovers. Their accuracy avoids damages caused by accidental drops or scratches. Using packaging robots can even prevent contamination in industries where it can be an issue like medical or food & beverage.

With the 6 axis robots, their movements, similar to the human arm, bring agility and allow for more complex manipulations. Packaging robots can also have a small footprint because of their capacity to be mounted in numerous ways. This helps save factory floor space.

Packaging robots require minimal maintenance and are capable of working in harsh conditions like fumes, dust and high temperatures. Unlike humans, they can operate 24/7. This increases the company’s production capacity without sacrificing the production efficiency and the quality of the product.

What to look for when choosing a packaging robot

Speed.

The packaging robot must match the speed of the production line. It helps speed up the whole production line and reduces the floor-to-market time of the product.

Flexibility.

The packaging robot should be compatible and flexible with a variety of product picking and placing. They could also be flexible to do other tasks such as labelling, palletizing, sorting, binning and more, if needed. Therefore, quick changeovers are a key point. Robots with a higher degree of freedom allow quick changeovers. There are automated tool changers available on the market which can reduce downtime.

Number of Axes.

Speaking of degrees of freedom, the number of axes is another key point manufacturers need to consider when investing in packaging robots. The more axes the robot has, the more flexible its actions will be. This minimizes downtimes and increases the productivity of the plant.

Budget.

This point tends to be overlooked, but the budget will help determine which compromise needs to be done to achieve the best ROI. To get the most out of a packaging robot, at DIY Robotics, we have a whole product line of affordable robotic cells. Contact one of our experts to find the perfect fit for your project.

Thanks to all the benefits mentioned above, like speed, accuracy, agility, and productivity, packaging robots are a great solution to boost profits. At DIY Robotics, we have succeeded in implementing all of the above-mentioned factors in our robotic cells. They are compact, customizable, mobile, and don’t require any specialist to program them. The cells are pre-fabricated solutions that enable manufacturers to simply plug and play them on their existing floor plan without any major changes in the blueprints. The integration of DIY Robotics modular cells on your floor will give you an edge over others on the market.

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WHAT TO KNOW ABOUT ROBOTIC CUTTING INSTALLATIONS – Laser Cutting

Industries throughout the world have begun evolving their workspaces to include robotic automation. Often, in large-scale manufacturing environments, these robots perform repetitive or dangerous tasks with little to no error. In any manufacturing environment, it is essential to find a high accuracy, speed efficient way to shape or cut materials and products. In turn, this will save money, keep the manufacturing process steady, and eliminate any hazards workers would be subject to if they were to operate the cutting equipment themselves.

There are various technologies available for automated cutting. Each with its own benefits based on the material used in cutting, and the rate at which cutting should be achieved. Here are a few of the most common cutting technologies:

  • Laser Cutting: mostly used to cut organic material, plastics, & metals.
  • Ultrasonic Blades: best suited for soft plastics, rubbers, & foams.
  • Punch and Die: most effective with plastics & metals.
  • Router: quite practical with hard plastics & metals.

This post will go into detail on laser cutting, and touch on the remaining cutting technologies in a later post.

Laser Cutting

As the name suggests, laser cutting is the process of piercing a selected material with a high-intensity laser. Using this focussed beam of light, the device heats up the material surface to a point where it melts or vaporizes. Therefore, it has the ability to carve, engrave, and separate most materials based on the intensity of the light, and the time spent under the laser. The majority of laser cutting systems have the ability to follow a specific path or geometry indicated by the user or operating system. This allows for complete automation of the cutting.

Different types of lasers are better suited for cutting certain materials. High-powered lasers are generally used for industrial applications where large scale or large quantities of metal or plastics need to be cut. Whereas low-powered lasers are more effective on thinner or weaker materials like wood and plastics. Presently, there are three main types of laser cutters:

CO2 Lasers

First developed in the 1960s, a CO2 laser runs an electrical current through a gas-filled tube (composed most commonly with CO2, Nitrogen, Helium, and Hydrogen) to generate light rays in the infrared spectrum. These light rays average from 50 to 100 Watts in power, however, industrial machines can typically generate multiple kilowatts. The CO2 laser is the most common type used due to it being efficient and inexpensive.

This type of laser is most commonly used while working with metal, wood, and various plastics. It also has the ability to work with food products, fabric, and other organic substances like leather and rubber. It is important to mention that this type of laser should not be used on materials that are reflective; as it can damage the laser via back reflections.

YAG/YVO Lasers

Also known as Crystal lasers, the YAG (Yttrium-Aluminum-Garnet) or YVO (Yttrium-Ortho-Vanadate) laser cutter is one of the more unique automated separation tools. Using a carefully constructed crystal medium, this laser allows for an extremely high cutting power, which allows it to cut through thicker and stronger materials. This is due to smaller wavelengths of light being generated by the crystals, and therefore creates a higher intensity beam than that of a CO2 laser. Due to their high-intensity cutting abilities, crystal lasers are typically more expensive and have shorter lifespans than other laser cutters.

These lasers are versatile with regard to their material cutting abilities. They can be used with both metals and non-metals, and are useful for a large range of applications, including medical, military, and manufacturing processes.

Fiber Lasers

This class of laser generates its cutting abilities by amplifying light rays using specially designed glass fibers. A massive amount of light can be transported through these fibers; combined with an extremely small focal point, the result is a light laser intensity much stronger than that of a CO2 laser. Typically, fiber lasers consume the same amount of energy as a CO2 laser but are more expensive due to their more effective cutting capability. This laser also requires less maintenance and therefore is a longer-lasting alternative to crystal lasers.

Fiber lasers are best suited for metals and strong plastics. Fiber lasers can also be used with glass and can cut reflective materials without fear of back reflections.

Safety

Due to the nature of laser cutters melting and vaporizing the working material it is crucial to ensure proper ventilation is established so no toxic fumes escape the laser’s workspace, and no human tissue comes in contact with the laser point. High energy laser beams can also cause severe eye damage and must be contained behind light shielding. Laser cutters are typically enclosed systems that will not operate unless the safety precautions are met.

That concludes the content for our current post. Stay connected with DIY Robotics and read the next post in the following weeks “What to know about robotic cutting installations – part 2” where we will touch on the remaining topics. If you have any questions regarding the above material or would like insight on one of the other blog topics, please feel free to contact us.

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Manufacturers in the USA – Last Chance to Avail the Benefits of Section 179

Did you know that USA-based Small and medium-scale (S&M) businesses, can save large chunks in tax?

Thanks to section 179, S&M businesses are or could be eligible to save tax money by either purchasing or financing specific equipment. This can help manufacturers upgrade to automation, save money, and utilize it to invest in the growth of their business.

What is Section 179?

Section 179 is a tax code, from the United States IRS, that allows manufacturers to claim and deduct the total PURCHASE PRICE of any equipment/software purchased, or financed from their gross income for the tax year. Its two main restrictions are that the equipment in question has to be installed and it needs to be in operation. The deadline for installing and putting this equipment or off-the-shelf software is the end of December 2021.  

Eligibility criteria

This benefit is only applicable to small and medium-scale businesses. To ensure this limitation, the maximum purchase limit cap is $3,670,000. Any industry spending more than the limit cannot qualify. 

Most of the equipment, off-the-shelf software, and business-use vehicles are covered under this scheme. This, of course, includes automation supplies like our DIY Robotics Cells. Businesses are also eligible to get a non-tax capital lease up to the deduction limit without having to pay any amount in 2021. The US government has made a dedicated page for detailed information which can be accessed on section179.org. 

All this can help S&M businesses capitalize on their hard cash and minimize their out-of-pocket expenses. Businesses, if eligible, can get up to 100% tax deduction.

How tax savings can amplify automation in S&M Businesses

Currently, S&M businesses don’t spend as much on automation as large-scale businesses. One of the main reasons is that automation doesn’t come cheap. This creates a gap between the profits and turnovers of large and S&M businesses. Section 179 acts as the bridge to fill this gap. It empowers manufacturers to run their businesses to maximum capacity.

This can help improve their production in quantity/quality and allows S&M businesses to utilize their money to fulfill other requirements without compromising on automation. Manufacturers can utilize their manpower more effectively with automation under the roof. It ensures better OEE, quick ROI, and various peripheral or tertiary benefits. It also enables S&M businesses to scale up when facing large-scale businesses in the competitive market.

The US government has created a great path to help small and medium-scale businesses. Manufacturers need to make the most out of section 179. It will enable them to compete fairly in this ever-growing market. Moreover, manufacturers can automate their businesses and even save their hard-earned money. So, what are you waiting for? If you were thinking of automating but haven’t made the move yet, know that our Robotic Cells are plug-and-play and deliverable within 3 weeks. This means you can have them in operation before the final deadline if you ORDER NOW.

Give us a call before it’s too late and get your modular and mobile robotic cell before the end of 2021. Don’t wait up!

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