Multi-Robot System Assembles Valves

Image courtesy of Edgewater Automation

Edgewater Automation designed and built a fully automated, multi-robot assembly system for a manufacturer of industrial valves. The system achieves a 2.5-second cycle time with an OEE of 85 percent. It features 31 robots, two linear-motor transfer systems, and pallet-transfer conveyors. The system includes vibratory bowl feeders; custom end-of-arm tooling; robotic screwdriving and riveting; robotic dispensing and curing; press-fit assembly, laser marking and robotic packaging. Quality checks include fastener torque, fastener depth, rivet height, leak testing, and vision inspection. 

Feeder Is Flexible

Image courtesy of Flexfactory LLC

The flexfeeder XQS presents a variety of parts to a robot for pickup without the need for custom tooling. The feeder gently presents parts on an illuminated vibratory table. A conveyor is not necessary. An integrated vision system identifies parts in the correct orientation for pickup. Brushless servomotors and high-quality, durable components ensure maximum ROI. A touch screen interface simplifies parameterization and provides performance data on feeding. Quick-change conveyor surfaces are available in different colors, materials and surfaces.

Orbital Riveters Are Modular, Flexible

Image courtesy of BalTec Corp.

The TN/E line of orbital riveters provide a force range from less than 1.5 kilonewtons to 35 kilonewtons. The line covers a range of applications and offers maximum flexibility for a variety of manufacturing processes. Thanks to a new adapter, the riveters can use orbital heads from other manufacturers, offering even more flexibility in production. The machines feature a protective device and meet CE standards—even without an enclosure—enabling the processing of larger, bulkier workpieces. Thanks to its modular construction, the machines can be integrated into existing systems and expanded with a range of accessories, including process control systems, hold-down devices, custom enclosures and automatic sliding tables. 

Adhesive Bonds Nylon

Image courtesy of Permabond Engineering Adhesives

TA4550 is a toughened acrylic adhesive that forms structural bonds with nylon and other substrates. This high-performance adhesive resists shear, impact, vibration, chemicals and environmental conditions. It bonds with nylon and other low-surface-energy plastics, such as polyethylene, polypropylene and PTFE. It also bonds metals and composites. This two-component adhesive is mixed at a 2-to-1 ratio. It requires no surface primers or additional surface treatment before bonding. This high-viscosity, non-slumping adhesive is formulated for controlled, accurate dispensing, even in vertical applications. It comes in 50- and 400-milliliter cartridges. It is also available in bulk. It cures quickly at room temperature.

Water-Resistant, Biocompatible Cyanoacrylate

Image courtesy of Panacol-USA Inc.

Cyanolit 290 WR is a moisture- and water-resistant cyanoacrylate adhesive. This instant adhesive has a fast-curing time and high bond strength with metals and thermoplastics, such as ABS and PVC. This solvent-free, one-component adhesive cures within seconds by reacting with atmospheric humidity. After just a few minutes, the adhesive achieves a tensile shear strength of up to 16 megapascals on metal. The bond retains its strength after several hundred hours at 85 C and 85 percent humidity. It also maintains its strength after exposure to engine oil, isopropyl alcohol and water. The adhesive has been tested in accordance with DIN ISO 10993-5 and is suitable for use in medical devices and wearables.

Servo Pump for Low Pressure, Small Shot Volumes

Image courtesy of PVA

A Servo Rod Pump (SRP) is the latest option for PVA’s Endurance dispensing module. The pump is ideal for dispensing medium- to low-viscosity materials with shot volumes of 100 cc or less. It bridges a gap for manufacturers who are interested in servo-driven metering technology, but do not require a high-pressure system. The SRP is a fully programmable metering system to precisely dispense material with and without abrasive fillers. The pump features a tungsten carbide metering rod with lip seals. The rod never contacts the cylinder walls. The rod’s bearing supports are external and do not contact any abrasive media. The mix ratio can be set from 1-to-1 to 10-to-1.

Tape Creates Fast, Strong Bonds

Image courtesy of Ellsworth Adhesives

VHB Tape Max from 3M is twice as strong as the company’s standard VHB tapes, enabling engineers to reduce reliance on fasteners and liquid adhesives. A priming liquid works in tandem with the tape to provide extreme strength. Suitable for both interior and exterior applications, the tape bonds similar and dissimilar materials. Applications include bonding stiffeners, brackets, rub rails and trim. It can also be used to attach panels to frames. As a 3M Preferred Converter, Ellsworth allows designers to create custom shapes and formats that simplify final assembly. The tape’s ability to deliver quick, high-strength bonds without intensive labor input makes it especially suited for today’s assembly lines.

System Tracks Position of Fastening Tools

Image courtesy of Sarissa GmbH

The PositionsBox Gen2 determines the position of an assembler’s hands and tools in three-dimensional space in real time. With the QualityAssist software, the system supports assemblers through guidance and laser-based visualization. It can manage an unlimited number of fastening positions and tools in real time. Multiple assemblers can be guided simultaneously using a laser projector. The system shows assemblers where and when to install each fastener, documenting the assembly process and ensuring compliance with specified tightening sequences. For added safety, the system offers protection against high voltage. The system is compatible with various tools, regardless of manufacturer. The position transmitter can be powered directly by the tool’s battery, and the system is easily integrated into assembly lines.

Controller for Blind Fastening

Image courtesy of Industrial Rivet & Fastener Co.

The MTC tool controller provides process control and data collection for the company’s full line of FreeSet cordless tools, including the RK-777C for blind rivets, RK-787C for rivet-nuts, and RK-797C for lock bolts. With the ability to manage up to 20 tools simultaneously through a wireless LAN, the controller prevents incorrect assembly by ensuring that each rivet is installed to specified parameters. The unit securely stores riveting data, ensuring traceability. Up to 100,000 results can be stored directly on the device. Programming is done through a web-based interface. All connected tools can be programmed directly via the controller. It supports multiple communication protocols, such as Ethernet and Profibus.

Current-Controlled Screwdriver

Image courtesy of Nitto Kohki USA Inc.

The DLV45C/DLV70C Series is a high-performance, brushless electric screwdriver equipped with current-control technology, offering precise torque management and flexible configuration options for a range of fastening applications. Torque ranges from 5.3 to 62 inch-pounds across two models. Speed can be adjusted from 400 to 1,200 rpm. The tools feature nine speed levels, plus a three-step automatic speed function. With 30 programmable channels, engineers can customize torque, speed and fastener count. The tool also provides real-time feedback through multicolor LED indicators.

Tool Features Rotating and Static Torque Sensors

Image courtesy of HST USA Inc.

The TorqBee EC2 series of cordless fastening tools are equipped with both a rotating and a static torque sensor. The rotating torque transducer acts as a master and controls the tightening process. The static transducer monitors the results of the rotating transducer in real time to ensure that it is working perfectly. Both sensors work with different, clearly separated technologies. This redundancy ensures that the fastening process is always safe and reliable. The tools can be used for tightening class A bolts in accordance with the VDI/VDE 2862 standard. The tool can store 150,000 results and graphs from both sensors for process documentation. The tools can connect to a network through a built-in WLAN module.

SCARA Robot Is Fast, Precise

Image courtesy of Epson America

The GX-C Series SCARA robots are designed for the most demanding assembly applications. The robots are available in multiple arm configurations for increased productivity and worker protection while minimizing footprint. Gyroplus vibration reduction technology optimizes throughput by enabling high acceleration, smooth motion and fast settling time. The robots work with the RC800A robot controller, which optimizes run-time, recovery and error handling. SafeSense technology enables human-robot interaction without requiring a safety fence. Options include vision guidance, parts feeding, force guidance, conveyer tracking, and fieldbus connectivity. Four models are available covering a reach range of 250 to 1,000 millimeters.

Cobot Is Easy to Program

Image courtesy of Omron Automation

The TM S Series of collaborative robots are suitable for a range of applications. Five models are available covering a reach of 900 to 1,902 millimeters and payloads of 5 to 25 kilograms. With 31 safety features, the cobot meets ISO 13849-1 (performance level D) and ISO 10218-1 safety standards. Applications can be programmed using a built-in hand-guidance function: Engineers simply move the cobot’s wrist to the desired position, and with the click of a button, the position is taught. A touch-screen interface can be used as a teach pendant. The cobot has an integrated vision system. Engineers can set up applications for immediate deployment without having to integrate external cameras or lighting.

Robotic System Automates Sealing of Holes

Image courtesy of IPR Robotics LLC

In the automotive industry, holes in car bodies often must be sealed prior to coating or painting. The PSH system is a fully automated, robot-assisted technology for reliably sealing holes and cavities in car bodies, batteries and other assemblies. The system accurately seals holes in seconds. Manual rework is not required. The system adapts easily to variations in hole diameter and part geometry. The system requires no disposable materials.

Modular Soldering Robot

Image courtesy of Elmotec, by E-Tronix

SolderSmart MAX is modular gantry-style robot for automated soldering. Engineers can choose from three heating technologies: laser, induction or conventional soldering iron. The machine can be used as a semiautomic, standalone system, or it can be integrated with a transfer system for fully automatic, inline production. The feeder can accommodate wire diameters of 0.5, 0.8 and 1 millimeter. The system is equipped with a vision system for accurate inspection of soldered joints. The robot compensates for part misalignment by checking the position of fiducials. Process parameters and results are stored in a database. The machine can read bar codes and store data with part numbers.

Free Software Generates Kanban Cards

Image courtesy of Arda

Arda has launched a free online tool for creating kanban cards. Originating from the Toyota Production System, kanban is a visual method for managing manufacturing workflows. It operates on a “pull” principle, in which replenishment is triggered only when needed, minimizing waste, reducing overproduction, and ensuring a continuous flow of materials. Traditionally, this involves the use of physical kanban cards that signal the need for more parts or materials. Arda takes the concept into the 21st century by offering a sophisticated inventory management system that connects physical kanban cards to a robust digital platform. The cards have QR codes that, when scanned, trigger automated reordering processes, eliminating stockouts and providing real-time inventory visibility.

AI-Based Software Detects Defects

Image courtesy of Loopr AI

LooprIQ Inspect software uses machine vision and artificial intelligence to identify defects quickly, accurately and consistently. The software is configured to identify the exact defects or anomalies that occur in a manufacturer’s parts or materials. The software detects scratches, cracks, bent tips, incomplete welds, foreign objects and anything else that a human inspector can identify. Defects are identified in real-time, logged in a database, and communicated to PLCs for fully automated operation. The software can run in auto-pilot mode for automated production or co-pilot mode to enhance processes requiring human inspection. Engineers can use the defect database to analyze and identify the root causes of failures. It can also be used to train custom large language models.

ERP Uses AI for Outcomes-Based Pricing

Image courtesy of Epicor Software Corp.

Epicor Prism Business Communications is the first ERP AI agent with outcomes-based pricing. The software automates RFQ workflows and accelerates supplier communications, helping supply chain businesses cut cycle time, reduce manual work, and make fast, confident purchasing decisions. The AI agent meets users on a familiar channel they use every day—email communication—without requiring separate portals or predefined templates. Because the software understands Epicor’s unique ERP data structure built for the supply chain industries, the agent can carry on a conversation with a user and contextually translate email communications with suppliers such as “lead times,” “cost,” and “part ID” directly into the ERP. 

Automated Torque Data Collection Software

Image courtesy of Pico MES

Kolver, a supplier of fastening tools, has launched K-Net software for torque data collection. The software is brand agnostic; manufacturers can connect their favorite torque tools and collect torque and angle data, all through a single interface. Designed to replace manual data tracking systems, K-Net gives manufacturers complete visibility into their fastening operations, automatically and in real time. With one fee, manufacturers can connect an unlimited number of tools or spindles. No subscription is necessary, and there is no per-spindle licensing. K-Net is powered by Pico MES and sold exclusively through Kolver.