EQUIPMENT FOR CUTTING AND MACHINING OF ALUMINIUM PROFILES
ASSEMBLY LINE FOR THE PRODUCTION OF REFRIGERATED CABINETS AND SHELVES
TWO CONVEYORS FOR COOPERATION WITH SMI PACKAGE SEALER
MANIPULATOR FOR CARRYING BOTTLES
TWO INTEGRATIONS OF COLOREX LINES
VISUALIZATION OF WORK OF REACTORS
SYSTEM FOR THE PRODUCTION OF PHTHALIC RESINS
POSITION FOR CUTTING TUBES
TURNTABLE FOR COUNTERS AND GRIPPER FOR THE DOOR
DOOR AUTOMATION SYSTEM FOR PAINT SHOP WITH GAS CONSUMPTION MONITORING AND AUTOMATIC CONTROL OF FURNACE PERFORMANCE
PAINT PRODUCTION LINE
PAINT MIXER WITH TENSOMETRIC WEIGHT
TWO STATIONS FOR ROBOTIC DEPALLETIZATION AND MIXING MULTI-PACKS FOR DRINKS IN PET BOTTLES
TWO STATIONS FOR ROBOTIC PALLETIZATION OF PAINT PIGMENT
TWO ORIENTATORS FOR BOTTLES
CONVEYOR FOR COUNTING MAGNESIUM ANODES
MANIPULATOR FOR CARRYING BARS
ROBOTIC STATION FOR PALLETIZATION OF STRETCH FILM ROLLS
LIFTING SYSTEM FOR A FLAP FOR LOADING FRUIT
We prepared the device for one of the leading manufacturers in the ladders and scaffolding industry. The machine is designed for the production of aluminium steps for ladders, for cutting profiles to size and for machining them. Such steps are ready for placing in a ladder.
The device is equipped with a storage box of raw profiles, which are fed into the cutter. The operator is responsible only for loading the raw profiles and entering the required length of the profile. Profile measurement is done automatically by the sensor and measuring roll. The machine has a cutting length optimization function. After sectioning a profile, a rectangular hole is cut out in it and mounting holes are drilled.
Such device allows you to speed up the production, but also reduce the amount of waste produced thanks to automatic optimization. Operating the machine is simple and safe for employees.
At the request of the manufacturer of refrigeration equipment, we designed, manufactured and implemented a semi-automatic assembly line for the production of refrigerated cabinets and shelves. The aim of the project was to improve the assembly of large refrigerated counters (width from 1m, height 1.8m, weight 250 kg). The assembly line is 66m long and consists of conveyors, scissor lifts, a platform and a roller conveyor. The assembly of the equipment is carried out in a cyclic system of work. The transport to the place of assembly is done by belt conveyors and a hydraulic scissor lift. Then the devices are transported from one production cell to another, where the components are assembled. The assembly line is based on 14 production cells. The station is equipped with a control panel, which allows you to set and change the cycle as required. Each production cell has a control cabinet, which allows an employee to pause the cycle. Therefore, one can control and adjust the assembly time at particular cells via the operator control panel. An assembly cell also includes a 12m long platform, which allows employees to work comfortably with elements placed at heights. At the end of the line there is a roller conveyor with special cutouts to allow the collection of an assembled cabinet or shelf by a forklift truck. The semiautomatic assembly line we implemented has facilitated the work of the employees on the assembly of refrigerated cabinets and shelves, improving both comfort of work and efficiency of production.
We supplied a confectionery plant with two conveyors for an SMI package sealer. They transport packeges with cookies. The first stage is a belt conveyor with variable speed which ensures easy and steady infeed of product into the shrink tunnel. The second stage, a roller conveyor, collects the package of biscuits after the sealer and enables their buffering. In addition, the conveyor can be easily adjusted thanks to the wheels.
We designed and implemented a manipulator for carrying bottles for a cosmetics manufacturer. The purpose of the machine is transferring bottles coming out of filling and capping station onto the conveyor leading to the labeller. The bottles in plastic baskets are transported on the conveyor and stopped under the manipulator with the use of valves. A set of four bottles is put together, and then they are raised by a gripper and moved onto the second conveyor. The gripper holds the bottles with the use of pneumatic jaws. While a set of bottles is collected the traffic is stopped, the lock releases when the gripper is lifted and new bottles are lined. The use of the manipulator allowed for the reduction of production costs and for improvement of the process. The advantage of this solution is its simplicity. The device consists of a manipulator, a gripper system, a system of sensors and mechanical interlocks.
We did two integrations of production lines for a company manufacturing ingredients for paint production. We introduced a system that integrates all devices on the line, starts and stops them in the right sequence and monitors their performance. The devices do not need to be "supervised" or operated manually by employees. Thanks to that, the lines run smoothly, flawlessly, without downtime, and production has clearly increased. In addition, we implemented a visual quality control system of product packaging. All systems are equipped with sensors that warn in case of problems on the line.
It is another project done for the company manufacturing ingredients for paints, and was made on a chemical installation for the production of phthalic resins. The project consisted in the installation of electrical system, preparation of control cabinets and start up of measure and control system. The system is equipped with SIEMENS controller and SCADA CIMPLICITY to 700 I/O. There are operator touch panels and two workstations equipped with four-screen preview of the installation.
Our Client is a leading manufacturer of equipment for work at heights. Mass production of ladders requires precision in cutting tubes. By way of agreement with the Drabest Company, we have taken up the design of a station for cutting tubes. It is a safe station that requires only one man for its operation. The operator is responsible for placing tubes into the device storage, setting parameters and turning on the device, the rest is done automatically in a cycle. Cutting line is accurate and repetitive. Any interruption in operation is signalled, so there is no need to "supervise" the machine. The machine consists of: - cutter with a bumper and base - feed table - buffer table Operation is simple. The position is fenced and has a safety system.
We designed, manufactured and implemented a turntable and a gripper for refrigerated counters.These devices were designed for one person to effortlessly mount a door on a large refrigerated cabinet. The turntable for counters allows for ergonomic positioning of a high cabinet (horizontal position), and the gripper facilitates efficient assembly of the door.
Once again, we prepared a system for optimization of gas consumption for a company producing refrigeration equipment. For that we modernized the furnace by adding adjustment of the furnace opening depending on the size of the element entering the furnace. This minimizes heat loss and reduces gas consumption. We installed monitoring at several locations of the furnace, we integrated it with the control software of the furnace, through which there is the possibility of downloading information on gas consumption. The investment allowed to save an average of approx. 20% of the gas. In addition, we introduced a system that collects data and visualises the operation of the entire plant (the assembly lines, the paint shop, the gas consumption, the water temperature).
We were asked by the manufacturer of construction chemicals to set up a line for the production of paints. The station is designed to automate the process of filling and closing of 1-15l buckets. The buckets placed on a plate conveyor are transported to the turntable, where where external devices start their work (e.g. filling). After leaving the the turntable the bucket is transferred to the closing unit, and then goes to a roller buffer, where it is collected manually.
At the request of the plant dealing with i.a. production of paints and varnishes, we manufactured and set up a system for weighing and for mixer control and a mixing visualization system. The proposed operator terminal is equipped with a touch screen, and the visualization is legible and clear to every employee. The user can choose options: "Manual", which allows for manual dosage of materials (dosing on/off) or dispensing a predetermined quantity of an ingredient. The system also signals hazardous events. When such an event appears on the operator panel, along with a alarm signal - the panel will show information about the type of danger, the cause and procedures. The main advantage of the system is its simplicity and intuitiveness of use.
The station is for a mixed palletization of multi-packs of drinks of three different flavours. The role of the operator is only to place full pallets in the boxes and collecting empty ones. We used: • the Kawasaki robot, which scans the layers of multi-packs and transports the product with high precision • a gripper allowing for collecting the multi-packs and inserts and placing them in the appropriate boxes • a sorting conveyor, lining the product on the conveyor • plate conveyors (50 mb) to transport multi-packs Our solution not only relieved the employees, but also increased efficiency by more than 40%, i.e. from 120 to 172 pallets per shift.
The task of the robot is collecting individual multi-packs of pigment from the roller conveyor and stacking them on pallets. The workspace of the station is only 1.2 x 3 m. The task of the robot is collecting individual multi-packs of pigment from the roller conveyor and stacking them on pallets. The workspace of the station is only 1.2 x 3 m. We prepared: • mechanical structure of the station, together with boxes for pallets and dividers and panel fence with safety guards • software for the Kawasaki robot • positioning and separating mechanism for the multi-packs • roller conveyor • safety system The stations we prepared provide high performance and precise positioning of multi-packs on a pallet. Palletizing is conducted in a continuous, trouble-free, quick and safe way.
We did another project for a company producing ingredients for the manufacture of paints - we prepared and implemented two bottle orientators. The machines are designed to bring the bottles in proper position on the filling line. The bottles are transported from the hopper to the sorting drum and the manipulator, where they are properly rotated and adjusted. They are transferred to the filling line with the belt and plate conveyor. We used: • feeder with hopper • sorter with a rejecter • bottle handling system • belt and plate conveyor Our solution has facilitated work and accelerated the production on the filling line. The infeed of properly oriented bottles reached approx. 120 pcs./min. In addition, the device is simple to use and does not take up much space.
For a LED lighting manufacturer we designed and constructed a photogoniometer for measuring the strength of fluorescent lamps. It is a laboratory instrument used to determine the light distribution of the tested fixture. A photogoniometer works in two axes: gamma and C. The project has used a special light meter - fluxmeter.
We delivered and set up an automatic counting machine for magnesium anodes for a production company. The device is designed to transport and count anodes. It consists of a conveyor equipped with cleats and a special optic sensor. An employee places anodes between the cleats on a belt conveyor. The product is transported to the storage bin. While falling into the bin an anode crosses the beam of the optic sensor giving a signal to the device to count another piece. The counter allows you to count to a predetermined value or count continuously. We provided a support system for the counter in case of power loss. Our device helps employees in completing delivery to the customer. It speeds up the process of preparation of the product, prevents errors and facilitates the work of employees.
We have implemented another device for the company providing storage systems. The device facilitates assembly of pallets for storing tires. We designed and constructed a manipulator for carrying bars. The device is designed to assist the transfer of bars, or steel pipes being components of pallets. We used separators, which allow for convenient storage of bars stacked in layers. The operator using the manipulator collects a layer of bars from a stack and places it in the appropriate location on the pallet. The manipulator is operated with the use of a convenient steering wheel with an operator panel, which requires less effort. The bars are lifted with the use of a chain hoist, which can carry 12 bars i.e. 80 kg at once. The manipulator with the hoist is mounted on a beam under the ceiling and may rotate and move in two axes in the plane. The gripper of the manipulator is fully pneumatic. In addition, we applied appropriate safety measures – a special valve – preventing uncontrolled collapse of bars in the event of a sudden power shortage. The use of industrial manipulators for handling heavy products is very helpful. Firstly, it relieves employees and accelerates the process. In the case of Arcom company, assisted transport of bars on the palettes significantly improved pallet assembly.
We designed a robotic station for automatic packaging of stretch film for a leading manufacturer of foil. The packaging process of the foil would be heavy physical activity for people. This is caused by the weight of the rolls, which can reach 40 kg. The problem is also the shape of the rolls, which are very bulky. In order to handle these issues, the customer ordered a solution that provides performance and reliability. We designed a station operated by an industrial robot with a specially designed gripper. The station is responsible for lifting pallets of different sizes, spacers and rolls with foil. The system uses two wrappers, as well as a pallet transport system for the collection of the packed product by the operator and a laser marking system. The whole is complemented with a roller dump system at the machine and pallet boxes that store pallets, dividers and corners. The system used at this station collects rolls, arranges them in various formats defined by the customer, wraps them and puts on corners and protective foil. In addition, the station weighs raw pallets and pallets with foil and sends data to the ERP system.
The system is built on the basis of two electrically driven rods. They allow you to raise and lower the flap. Semaphores placed at the entrance and exit inform the driver about the possibility of entry and exit from the loading dock. The operator has the ability to control the flap manually using special buttons. he whole mechanics was constructed with extreme care. Our priority was to secure the equipment against corrosion caused by weather conditions, as well as water used while unloading. The whole project was completed within 3 weeks. Those three weeks included the design, the construction of the mechanical parts and receipt of the system by the customer.