Category: blog

Upgradation of Schuler Press in Automation

Upgradation of Schuler Press in Automation

 

Challenge: Schuler Hydraulic Press was available with customer ,we had to provide electrical solution and automate the same.

Solution: Since machine was available with customer and we had to automate the same. We provided Electrical Panel and automated / synced the data with the Robot.

Working: This  Hydraulic Press Machine works under the pressure of maximum 350 tons and 600 mm/s speed. Press and speed are variable according to customer command in HMI. This machine auto picks up the piece ( say axle) and exit the same with the help of other robot.

Both the Robot communicate with PLC ( Rockwell’s Compact Logix) at Ethernet / IP Protocol. The output  is 4 piece in one cycle.

First Robot auto picks the piece (say axle)  and puts on transfer 1 , the time is synchronized in a way that it does not collide with other piece. Hydraulic press comes on transfer 1 , a step is formed with increase in height , then it is shifted to transfer 2 and the process repeats till last transfer and is then automatically picked by output Robot.

This process is done by cold extrusion. Earlier this process was done by Hot extrusion. Cold Extrusion is better than hot extrusion the product is of high strength , step is formed by hydraulic press i.e no machining required from third party. And there is no material wastage.

System Integrator for Rockwell Automation in North India

Reckers Mechatronics Pvt. Ltd.

Reckers Mechatronics was established in 2008. We are one stop solution provider for Industrial Automation, Utility Management System, Energy Monitoring System, DG Synchronization, SCADA Utility, Digitization and Reporting, Test And Measurement Applications, Mechatronics and Robotic Solutions. We are serving diversified customers with office locations at Faridabad and Chandigarh.

We are an ISO 9001:2015 Certified Company. We are RcSI for Rockwell Automation. Rockwell Automation delivers the automation components and integrated control systems one needs to optimize performance.

We provide focused solutions, install and upgrade the automation systems to deliver integrated solutions to Industries for different applications.

We as a solution provider help industries to achieve the following:

1 Increase production
2. Cost effective manufacturing outcome.
3. Improve quality
4. Reduce downtime
5. Reduce wastage
6. Reduce production cost

Performance Monitoring Service in Haridwar Himachal Pradesh Delhi / NCR Baddi

Performance Monitoring

There are different ways of performance monitoring; it can be of a machine or a line in a plant. One standard measure is measuring the OEE.

OEE stands for Overall Equipment Effectiveness, it can be calculated as:

OEE = Availability x Performance x Quality

OEE

Challenges Faced by Manufacturing Industries:

Here are few challenges faced by manufacturing industries during production in a Plant:

  1. Different Information required by departments.
  2. Small Units of Information which is to be gathered.
  3. Manual Logging and Reporting.

 1. Different Information required by departments:

In a manufacturing Industry there is different information required by persons handling different departments. For instance: During production of a product in Industry, Plant Manager wants to know the new Order Capacity ; Operations department want to know how the process is going against the plan etc.

2. Small Units of Information to be gathered:

There is information available with each department and to take a decision it is required to gather all the relevant information

3. Manual Logging and Reporting:

Usually in manufacturing Industries, the information is collected from different departments in Log sheets form and then is compiled to form reports.

Flaws of Manual System:

  1. The data is compiled and then reported. Thus, it is not Real Time data.
  2. Data collection and reporting is tedious and time consuming, can be inaccurate.
  3. Data can be manipulated.
  4. Requires a lot of productive time.

Role of OEE with help of Rockwell Automation Software:

There is software called Factory Talk Metrics which is connected to the data sources in different sections of a plant. It picks up relevant data and then represents in the form of reports, which can be viewed in Real Time through web, i.e. online.

Thus, information can be provided to different stake holders for their analysis and thus timely decision.

BENEFITS of OEE:

Here are few benefits of OEE:

  1. We can track the performance of earlier shifts too.
  2. Multiple operations and multiple products can be produced on the same line.
  3. We can get important insights on How to systematically improve manufacturing process.

 

Industrial Digitization

Industrial Digitization

Industrial Digitization is essentially getting the data and process networks converge across internal departments of the organization and geographical boundaries. The digitization may affect various aspects like new consumption patterns and information processes.On one side, digitization comes with a question of how the principles of Industry 4.0 or can say how the utilization of technology can help us to extend the efficiency, quality of production/ manufacturing.  Also how it’ll help to extend the security of processes and structures.The digital factory or smart factory plays a lead role during this . The global digitized networks are created round the smart factory through the utilization of consistent assistance systems, comprehensive adaptive systems and data technologies. This allows very flexible and efficient manufacturing up to economic manufacture of individual product. This mainly helps engineering, manufacturing, supply chain management and custom management.On the opposite side, the goal of Industrial digitization is developing smart products and services to take advantage of the potential IOT for revenue and new applications or developments.Thus, smart products will perform autonomous tasks by exploiting integrated connectivity, sensors and computing capacities, coordinating centrally and decentralize via cloud platforms and adapt to changing environmental conditions and tasks.
Also, smart products from the basis for the development of services which is known as predictive maintenance.Industrial digitization thus means the introduction of latest innovation, work organizational principles in supply chain of the manufacturing industry and their integration with lean principles.

Transformation of Manufacturing Industry through Digitization

Transformation of Manufacturing Industry through Digitization

Definition of Digitization:

Industry Digitization is the first step towards Industrial Internet of Things (IIOT). In simple words digitization is a process of turning non-digital formats of information into digital formats. Like clay models into CAD files, letters into emails, hardcopy report files in excel reports etc.

Most important point is to keep the processes and systems same when processes are digitized. It is also called making the industry go Paperless.

Few transformations in manufacturing industries:

Here are few transformations that will take place in manufacturing industries if digitization is introduced:

  1. Speed of Manufacturing will Increase

The speed of manufacturing industry is going to increase with digital transformation,

For instance the system will move fast from design to floor and back again as the changes required from engineering team.

Now days the process is manual in many cases. First 3D designs are converted into 2 D books and then 2D books are delivered to machinist to review and then the same is returned to engineering team for amendment if any.

 

The inefficiency that is taking place in manufacturing industries is:

  1. It consumes lot of time and man hours.
  2. Factories are usually globalized sending exact information may get time taking.
  3. No auto-check facility and it is tedious task to further innovate to optimize the process.

Hence, Digitization makes the process more efficient and fast.

  1. Making the manufacturing process globalized:

We all know, in any manufacturing industry there are different plants operating same or different processes related to the specific product. Through digitization we can share the data globally without any delay.

For instance as one plant closes for the day and the other one with different time zone is opening up , required data or information can be shared seamlessly without any downtime.

Thus, digitization enables to share the essential data in real time across multiple global locations.

Also, enabling data to be accessed in real time across different places in the world impact on innovation trends and creates new opportunities.

Once the processes are digitized then additional technologies like machine learning, AR, IIOT, machine intelligence, IIOT, Industry 4.0 and complete life cycle can emerge.