Projects
We would like to present some of our projects below. Unfortunately, due to our NDA obligations, we are unable to provide most of them. However, similar projects will certainly be repeated in the future!
Industrial Branches
Food & Beverage
It turns out that you can create tasty and healthy products in a traditional way, using industrial machines. The key to success is the proportions of the selected filling ingredients and the quality of the dough, selected over the years.
However, do you need a human being to pre-roll, knead, cut, separate and position the dough on the baking sheet? The project assumed a comprehensive modernization of the control of a bakery line for the production of food products from dough. The technological line consists of five modules where each module corresponds to one PLC controller. Drivers embedded in machines left the market many years ago and it is more and more difficult to find them even on the secondary market due to the fact that failures appear more and more frequently. The implementation goals agreed with the client assumed:
• Replace all five drivers with the latest compact driver series available
• Replacement of two increasingly harder-working operator panels with larger ones, with new process visualization
• Creation of an easier from the diagnostic side and faster way of communication between the controllers
• Establishment of remote access and line service
• Creation of a number of new functionalities indicated by operators improving production activities To meet the above customer requirements, we decided to rewrite all the programs and the synoptic layer.
The total downtime of the line from shutdown to fully operational production was 13 working days. We are pleased that we were able to help the client in this project and at the same time congratulations on the decision to replace the control layer, which will certainly serve for the next several years of uninterrupted production.
The project implementation time is 1 month. We invite all companies from the bakery industry to cooperate with us, and enclosed some photos from the project.
The FDA-certified conveyor belt adjusts to the performance and operating modes of the weighing machine. Additionally, we designed and made a charging hopper in accordance with the dimensions discussed with the client.
The project implementation time is 2 weeks. Manufacturers of control systems used in the machine (Mitsubishi Electric, Delta)
The project assumed the redesign of the module supporting the process of weighing loose materials (flour, breadcrumbs) and pouring the weighed amount into the packaging.
The project implementation time is 5 business days. Manufacturers of control systems used in the machine (Mitsubishi Electric, Wobit)
The project concerned the preventive replacement of the driving layer in a packaging machine for one of the leading Polish producers of confectionery products. The aim of the project was to recreate the functionality of the machine on new servo drives available from the manufacturer. All drives operated in speed mode, therefore the most important thing was to correctly measure the parameters of the drives before the modernization.
The project implementation time is 7 business days. Manufacturers of control systems used in the machine (Mitsubishi Electric, ABB)
Automotive
We participated in the implementation of two projects regarding the folding and packaging of curtain-type airbags. The service concerned comprehensive programming of the machine’s functionality.
The range of components that require software is: 5 servo axes working in synchronous mode 2 industrial cameras Operator Panel Safety controller Pneumatic layer HMI panel.
The project implementation time is 2 months. Manufacturers of control systems used in the machine (Mitsubishi Electric, Keyence, Sick, Festo)
The project assumed the integration of an industrial robot with a press for six selected parts and the creation of an easily adaptable program structure on the robot so that a maintenance engineer without expert knowledge in the field of robot programming could add and handle a new part.
The project implementation time is 1 month. Manufacturers of control systems used in the machine (Siemens, Fanuc).
CPG & Cosmetics
The aim of the project was to perform a visual inspection in the so-called flight (without stopping the machine) regarding the measurement of the dislocation of the applied and welded reflective foil on a cardboard format with an overprint. Due to the dynamic retooling of the machine, the main assumption was to create an intuitive and transparent synoptic layer allowing to change the parameters of the camera program to a new format for a user who does not have advanced knowledge of vision systems.
The system installed by us performs the measurement with an accuracy of 0.01 mm.
Manufacturers of control systems used in the machine (Cognex, Siemens) The project implementation time is 1 month.
The aim of the project was to comprehensively program the pourer equipped with 8 filling sections, and to measure the volume and weight. After stopping on the transporter of 8 bottles of dimensions resulting from the current recipe, a set of pouring nozzles on the servo motor rolls off to start the pouring cycle. Together with refilling the liquid, the nozzles are raised in order to eliminate the influence of pressure on the pouring process and the formation of any foam.
The delivery time is 1 business month. Manufacturers of control systems used in the machine (Siemens, Endress + Hauser, Festo)
The aim of the project was to improve the program for controlling a machine equipped with two SCARA robots. The bottle capping process was not repeatable and not acceptable to the end customer. The problem was not identifying the start of the thread on the nut. Together with the client, we made a decision to purchase two industrial cameras with illuminators selected by us.
The machine tightens 98% of the bottles correctly, which is an improvement compared to the original version in which the correctness of capping was set at 70%. The lead time is 1.5 working months.
Manufacturers of control systems used in the machine (Mitsubishi Electric, Omron)
Steel & Metalurgy
The project assumed the integration of an industrial robot with a lathe. Taking shafts from the pallet and placing them in the jaw of the lathe. In the project, we dealt with robot programming and security system integration.
The project implementation time is 1 month. Manufacturers of control systems used in the machine (Siemens, ABB)
Application related to the production of steel cabinets equipped with 3 six-axis robots. A fragment of a large application that was implemented by us is a robot with a load capacity of 240 kg, six-axis with three interchangeable tools. Each of the tools has four independent Tools. Each of the tools is equipped with several dozen pneumatic control signals. One of the tools has an industrial camera installed.
The robot serves 5 warehouse sectors from which it can pick up shelves with or without hangers, wreaths with or without hangers, wardrobe feet and hangers. The task of the robot is to coordinate the operation of warehouses and precise peeling of details, taking into account the maximum outreach of one of the planks over 1.9 m. After removing the shelf, the robot moves over the calibration position with a vision system, which checks the correctness of the download and sends the corrections to the robot.
The robot then places the shelf in the cupboard previously calibrated with a vision system, thus preparing the shelf for the welding robot. The degree of robotics advancement and the number of implemented functionalities of this application is at the highest level.
The goal of our company was not only to program the robot but also to share with the client many years of experience in robotic projects. It is the most extensive robotic application we have written so far, but we believe that even greater challenges await us.
The project implementation time is 3 months. Manufacturers of control systems used in the project (Kuka, Cognex, Beckhoff, Sick)
Wood
The aim of the project was to program the machine for the production of wooden cross fences from scratch. The machine has two manipulators and a 17-meter-long indexing plate conveyor. The manipulator automatically takes it from the warehouse and then places the pegs based on the successive plates of the transporter.
The project implementation time is 6 months.
Manufacturers of control systems used in the machine (Omron, Sick)
Media & Broadcast
The aim of the project was to create a system enabling the movement of a TV camera in the XYZ system with the assumed system span of 200x200m. The system is equipped with four winding stations, a pulley system and a camera mounting platform.
The operator controls the platform using a console with two joysticks (XY and Z). Winding stations operate in synchronous mode. Communication between stations is based on optical fibers.
The project implementation time is 6 months.
Manufacturers of control systems used in the machine (Mitsubishi Electric, Sick)
