Increased productivity through automation of loading and unloading
Automatic buffer lines used in existing paint shops enable:
- reducing the duration and amount of production downtime,
- shortening the duration of the painting process,
- reducing the number of mistakes (e.g. painting the wrong part),
- automation of the painting process,
balanced load on the painting line,
reduction of buffer space.
Economy and security
The operation of a paint shop is inextricably linked to health risks for workers. However, this can be changed by automating paint shop operations. By taking such a step you can gain:
- increased worker safety,
reduction in the number of production workers, - acceleration of paint shop operations,
- reduced number of accidents and mistakes,
- reduced spending on protective equipment for employees.
In addition, if you decide to go through the automation process with us, we guarantee that your new machines will be adapted to Industry 4.0 standards, which means lower costs for the company in the future.
Operating the robot in a confined space close to an overhead conveyor
Space in operating automated paint shops is limited. Automating workpiece buffering processes can significantly reduce the required space required for this task.
In the example presented here, we created a buffer line in an area where many installations ran low above the floor. This did not allow us to use standard solutions. Our entire buffer line occupies a space of only 153 square meters (17m x 9m). This allows a standard paint line to operate with greater efficiency.
We accomplished the task by designing a 142-meter-long Free and Power buffer line. Two Yaskawa robots were integrated into the buffer line.
Automatic retrieval of workpieces for painting from other systems. Integration of the robot with an overhead conveyor
Existing paint lines are challenging to automate. They often use different systems that operate separately.
In a paint shop operating for the automotive market (TIER 1), we integrated our buffer with an existing AGV cart system. The difficulty in the automation was the random order of the AGV carts with details, which are collecting semi-finished products from multiple stations. In this case, to reduce the cost of automation, we used only one four-port station to pick up unpainted parts and deposit the painted parts on the AGV carts. With this solution, we replaced the work of at least 12 employees.
Removing hangers from the overhead conveyor of the paint line
To optimize the use of space on the production floor. Instead of the work of 4 employees using manual grippers, a manipulator was used. The task of the robotic system was to remove workpieces and hangers from the automatic paint line and to de-prime it for the buffer line.
By implementing the solution, a large production space was saved.
P&F conveyor integration
Automatic buffer lines use Power and Free conveyor systems.
Unitem has used this type of conveyor to automatically buffer up to 5 different types of products for painting. This buffer line maximized the use of the existing systems operating in the paint shop.
Thanks to Unitem, this paint line operates in automatic mode 24/7. The solution has helped reduce downtime resulting from bad parts hanging on the paint line.
Robot integration with overhead conveyor of semi-automatic paint line
Standard buffer systems prevent workers from adding more parts to the same paint line. This results in reduced productivity or stops the production process.
Unitem has created a fully functional solution that allows workers and robots to operate simultaneously.
The presented solution allows for the optimal use of all company resources.
How do we implement projects?
FREE AUDIT AND PRELIMINARY DESIGN
The first and most important step in the process. Here, we will understand the problem to be solved or the process to be improved.
MACHINE DESIGN
AND CONSTRUCTION
Knowing the goal, we will design a solution. We develop the best possible design based on available technology, desired effect, and budget.
MACHINE
TESTING
The finished machine is tested with the use of parts provided by the customer. The tests are repeated until the machine has achieved all the goals.
EMPLOYEE TRAINING
AND MACHINE START-UP
Our specialists assemble and start the machine at the customer’s site. We provide the necessary training, schematics, as well as operating instructions.
Guarantee and safety
All the machines we build are safe and meet the most stringent requirements. Our machines are mainly based on PLC control. All the parts we use come from the best manufacturers. We closely adapt the project to customers’ requirements by developing concepts of operation and construction of machines together with them. We choose the most simple and most durable solutions when designing industrial machines and building robotic production machines. An example is our leak testing machines, where the proposed solutions reduce the test time up to 80% of the time. This makes the machines we build cheaper, more durable, and less complicated.
In doing so, we are not afraid to use non-standard ways of manufacturing parts. We also often offer customers alternative approaches to their production processes. This results in savings and increased durability of the assembly machines we build. We strive to establish long relationships with customers on a win-win business basis.
We are a recommended system integrator, so we have regular customers to whom we automate production processes.
Benefits
- Reduced process time
- No assembly mistakes
- Simplified the process
- Increased the production capacity
- Greater repeatability
- No production downtime due to machine problems
- Reduced employee training time
