free automation resources

5 Free Custom Automation Resources [Complete With Downloads]

Navus

Here at Navus, we’ve spent over 20 years tackling the biggest challenges in custom automation. We take our biggest wins and share those stories through free custom automation resources, letting you know how we can solve your automation challenges, create efficiency, and mitigate risks in your facility.

Engineering the Future with Remotely Operated, Multi-Function Robotic Workcells

Robots have been used in the past to perform repetitive, low-skill labor. However, contemporary tools and features provide them with a much broader range of capabilities. 

This includes:

  • Offline programming
  • Sensing
  • Tool changing
  • Remote monitoring

These features allowed us to design an extraordinary system for a client that increases safety as well as efficiency. They can now take advantage of a system that moves the robotic workcell 100 feet into position in an environment that poses certain risks to their employees. Meanwhile, the operator is able to work in a remote location where they’re not in any danger.

This allows the operator to oversee:

  • Joints being prepped
  • Welds being prepped
  • Inter-pass cleanings
  • Vacuuming of welds

With multi-function robotics, the new system is able to reduce risk to the operator and increase productivity. It also drives down the costs brought on by traditional methods due to time and expense in order to achieve the same goal. 

This helped our client:

  • Reduce safety risks in a harsh work environment
  • Save time and money by bringing the weld cell to the part
  • Improve the quality of welds with only one operator
  • Reduce man-hours by only needing one operator

 

Download our free white paper to learn more about how we were able to help our client with remotely operated, multi-function robotic work cells!

 

Custom Automation for Dynamic Productivity in Light Industrial Manufacturing

At Navus, we are adept at designing and developing projects at all scales and levels. We jump at every challenge to streamline complex processes and adapt them to your needs.

A perfect example is a recent client of ours who already had automated processes in their facility. These processes dealt with the production of a specific product, but they still needed help downstream for packaging without human intervention. Our engineers were tasked with creating new, custom processes and integrating them with our client’s current processes.

What made the project truly challenging were the stringent parameters they had to work in. This included goals, materials, and space. However, the product itself was complicated with multiple parts that required assembly. Our team had to design the new system with this goal and in the client’s parameters to be truly successful.

Fortunately, what would intimidate other companies intrigued us. We worked with our vendors to develop an automated process that exceeded our client’s imagination. 

 

To download the free visual case study and learn how we created a system that produced 24 parts per minute with only one operator, click here!

 

Transforming Medium-Industry Manufacturing Through Vision Guided Robotics & CAD to Path Generation

Using robotics in automation isn’t a new concept and many medium-industry manufacturers are taking full advantage of their potential. However, residential construction is still lagging behind. While building prefabricated residential structures may seem like a heavy-industry project, it’s actually just combining multiple medium-industry pieces into a larger whole. 

This is the challenge we faced for one of our clients. In the past, they had their employees measure and cut all the floorboards by hand for their prefabricated buildings. The main problem they faced was consistency. Each piece of floorboard required a different length so they would match the layouts in different building plans. They wanted to make their process more efficient.

What made this project especially exciting for our team is that the client didn’t have any pre-existing automation in their facilities. This would be their first, and we were thrilled to be chosen to develop it for them. They needed a process that would translate from 2-D CAD drawings to a finished product ready for installation. 

Our challenge was to create an automated process that required:

  • Vision-guided robotics
  • Custom software
  • Adaptability with minimal input from an operator

Although it seemed complicated on the surface, the Navus team had confidence that they could meet all the client’s needs. Not only that, but the new system resulted in faster production times and reduced safety risks. 

 

Download our free white paper to learn how we were able to help our medium-industry manufacturing client with vision-guided robotics and CAD-to-path generation! 

 

Making the Impossible, Possible with Sensor-Guided Robotics

Medium-industry automation isn’t the only field we work in. We’ve also had the opportunity to work in heavy-industry manufacturing where custom automation can provide a variety of benefits for clients. A recent client had worked with multiple custom automation specialists in the past who had failed. Fortunately, they eventually found their way to Navus.

Our client’s old manual process consumed time and exhausted the employees. Things needed to change not only to improve efficiency, but also to mitigate certain risks for employees. 

They gave us an opportunity to try the impossible and build a machine that could:

  • Locate individual parts that weigh up to 14,000 lbs
  • Identify parts by shape and features
  • Create a toolpath for parts
  • Mill sharp edges of parts to a precise radius

The client’s old manual process had employees using electric grinders to smooth sharp edges. This left them exhausted and significantly increased the risk of an incident. This new process helped ensure the safety of employees and allowed them to supervise the process from a safe distance.

 

To download our free white paper on using custom automation to make the impossible possible in heavy-industry manufacturing, click here!

 

Increasing Productivity in Manufacturing with New Weld Technology

The ability to weld heavy and complex parts is an important aspect of heavy-industry manufacturing. We were recently able to transform a client’s welding process from outdated and unreliable to one that’s much more accurate and safe.

Despite using 15,000 lbs of force to hold them in place, their old system had a tendency of parts slipping during the welding process. This was impeding their process by slowing down production as well as their throughput as a whole.

They knew they needed a solution that:

  • Produced accurate welds
  • Kept parts in place through the process
  • Kept their line operators safe

This project gave us an opportunity to partner with Miller Electric and beta test a brand new welding system. We were also able to design a unique spring-loaded system to prevent the slipping they experienced with their old system. 

Another important factor was creating a system that could hold parts that ranged from 50 to 1,500 lbs. Our solution needed to recognize parts of different sizes and follow the correct steps without human input. Faster welding times were also a must to increase productivity. 

Despite feeling nearly impossible at times, our engineers were confident they could meet the client’s needs. The end result was an easy-to-use system that integrated with their other processes to improve output and employee safety.

 

Download our free white paper to learn more about how we were able to meet our heavy-industry client’s custom automation welding needs!

 

Navus Automation Inc. is a leading full-service automation integrator. Our world-class team has a reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions. From concept to completion, Navus provides robotic welding and automation systems built upon our unwavering commitment to excellence, precision and reliability

First Navus Open House Was a Big Success!

Navus

We want to thank everyone who attended our very first open house last Friday! It was a blast to introduce so many of you to what we do for our clients every single day. We welcomed 100 different people to our facility in East Tennessee and demonstrated custom-built robotics, automated manufacturing lines, virtual reality technology, and so much more. 

Among attendees were class field trips from Heritage High School, engineering students from the University of Tennessee, representatives from the Knox County government, including Mayor Glenn Jacobs, current clients, and area partners, not to mention our wonderful friends and neighbors.

Thank you to our entire team for their hard work in making this happen, especially our Business Manager, Jennifer! We’re proud of the important work that we do, and the opportunity to show off some of our projects isn’t something we get to do every day! We enjoyed celebrating our accomplishments with all of you.

Overall, the day was filled with fun technology, delicious food, and wonderful company. If you weren’t able to make it to the event this year, we look forward to your joining us next time.

If you attended the event and would like some more information about partnering with us for your own custom automation needs, or are interested in current career opportunities, please contact us at info@navusinc.com.

Navus T-Shirt Design Competition for Open House in October

Navus

Want your design to end up on hundreds of T-Shirts? Now’s your chance! Navus is hosting a special Open House for the very first time on Friday, October 22 from 2pm – 7pm. All attendees will receive a free T-Shirt, and the design featured could be yours!

The theme for the event is inspired by 80’s Sci-Fi and Industrial design. BladeRunner, synth music, and Galaga should all be kept in mind. Imagine what the design schematics would have looked like for the Terminator and then apply that to assembly-line robots. Your shirt design should reflect this theme, but feel free to let your imagination run.

Rules:

All designs must incorporate the Navus logo, but feel free to modify it how you see fit. The logo file is available for download here: Navus Logo

You also do not need to use the Navus color palette. In fact, we encourage you to find inspiration from synthwave/vaporwave designs and color palettes.

The design should reference “Open House October 22, 2021”.

Art is limited to 5 colors.

Inspiration:

Need some more inspiration? Here’s what we’re looking for: 80’s Sci-Fi and Vaporwave meet Industrial and Technical. We’ve got a Pinterest board and a Spotify playlist to get you in the right headspace here: 

Pinterest – https://www.pinterest.com/navusinc/2021-open-house-t-shirt-design-contest/

Spotify – https://open.spotify.com/playlist/0cHYrgYfB9RH8NH85RbjJc?si=8220eb0d24fd46de&nd=1

Submissions:

Submissions for designs will be open to everyone until September 24, after which a winner will be chosen and announced. All submissions should be sent to info@navusinc.com as a vector file.

Prize:

The winner will be announced on October 1 and receive a batch of the final T-Shirts to give to friends and family along with a $500 Amazon Gift Card!

Submissions are open now, and we look forward to seeing what you come up with! Best of luck, and we hope to see you at our Open House Event on Friday, October 22 from 2pm – 7pm.

Robotics Demonstration Open House Announcement

Robotics Demonstrations at First Navus Open House

Navus

Navus is excited to announce our very first Open House happening on Friday, October 22, 2021!

The shop floor will be open for tours of our facility and its capabilities. Several of our custom-built automation lines and robotics will be on display, demonstrating their abilities alongside the engineers and technicians who designed them. This will be a chance to witness firsthand Navus’s services as well as an opportunity to meet with technicians and discuss their work. Come see how Navus uses state-of-the-art automation to solve problems for some of the finest companies in the world.

A variety of our technologies will be exhibited, ranging from sensor-guided robotics to tactical welding systems and everything in between. Our technicians can walk you through how our projects are developed from concept to the finished product. We’ll also show you how our turn-key solutions make our clients more productive, safer, and more profitable. 

Whether you’re interested in a career, the services we provide, or robotics, we are excited to showcase what we do for our clients every day and share the world of possibilities that automation provides.

All attendees will receive a free t-shirt, and if you’re interested in submitting a design for our contest check out the full details here.

Our doors will be open to visitors on Friday, October 22nd from 2pm – 7pm.

You will have opportunities to interact with our technology in fun and exciting ways. Also, refreshments will be provided throughout the event. Everyone who checks in will receive 2 free drink tickets and have access to an open snack bar

Join us for this free event on Friday, October 22, any time between 2 p.m. and 7 p.m. at 2640 Westcott Blvd, Knoxville, TN 37931. Please RSVP for this free event by Friday, October 8, 2021, and you’ll automatically be entered into a giveaway drawing. All attendees will receive free Navus swag, including a t-shirt!

We look forward to seeing you there!

Contribution in Custom Automation

The Team at Navus: Contribution in Custom Automation

Navus

At Navus, the majority of our team has worked at the company for years. Each one comes with a different professional and educational background, and a lot of them are hired with one position in mind. But a trend at our company is our team members discovering what they’re most passionate about in the custom automation process, and moving into that position as they grow with the company.

Meet David: Automation Technician

David P. has been with the Navus family since 2007. He’s done a variety of jobs, including welding, fabrication, assembly work, and now mostly operates our water jet and press break. We recently sat down and asked David to share his Navus story.

Passion for Fabrication

Navus: Describe what you do in your role at Navus.

David: I do a variety of things. Welding and fabricating. We do the automated machines, obviously, so that requires a lot of assembly work. But mostly I operate the water jet and the press break. I still do a little welding if they need some extra help with it, but mostly making parts for our machines is what I do day-to-day! I really enjoy it. 

The water jet cuts the material. It can cut a variety of thicknesses from 1/16” to 3” and a variety of different materials. It will even cut glass, cardboard, wood… You put it under there and it will basically cut it! It uses 90,000 PSI (pounds of force per square inch).

Navus: How did you end up in this career, and ultimately at Navus?

David: I was born into it. My dad was a sheet metal worker for 40 years so he always did custom cars at home. I’ve been welding since I was 5 years old. I studied some stuff about fabrication in the auto trade in school. I went to college for mechanical engineering, but I’m not an office person. I prefer to be in the shop. I worked in automotive painting for a while, but I really enjoy the welding side of that industry more. That’s what got me into this. 

The company I worked at before [Navus] had a huge warehouse and they had rented part of it out to Navus because of a big machine they were making. At the time, Navus needed the extra space. That’s actually how I got connected with Navus. They were interested in starting more of the welding side of fabrication, and asked if anyone at my job was interested! It’s close to home, and we’re always doing something different, which is really nice.

Navus: What’s your favorite part about your job and working at Navus?

David: Seeing the whole process to me is fun. Right now they’re finishing a weld cell, getting ready to ship it, [at the same time] keeping the ball rolling on all of our other current and upcoming projects. I’m always cutting parts for the next machines. I love seeing the whole process, from me cutting the parts, to the guys welding them together, to powder coating, to assembly, to seeing the machine run. That’s just always super cool. We’ve made some really neat machines over the years.

Obviously, we stay busy. But it’s a really great environment. Our team trusts each other, and no one micromanages what we do. It’s close to home. And once I get somewhere I like, I like to stay.

More Heads Are Better Than One

Navus: Describe some of the ways you’ve seen the team at Navus work together to overcome challenges.

David: The more heads you have in something, the better off you are as far as perspective goes. It’s just neat to see how people think differently to solve the same problems.

Navus: What have been your favorite projects to work on?

David: There’s a bunch. The very first one was a filter machine. It was stainless steel filters and the machine did the entire process. It would actually run it out, sheer it off, crimp it, stack it, and  have it ready to go. Another one was for a paper company. They had big rolls of paper towels and the machine would stretch out the paper towels and cut it off. I liked that one a lot.

I also love the project I’m cutting parts for right now. It’s a return client that wanted us to do more of a system we’ve already created and delivered to them. It’s for a product that a lot of people are familiar with, so it’s cool to be a small part of the process of the production for them.

Navus: What do you hope for your future at Navus?

David: I can’t wait to see what projects come in next. It seems we get something different every day to work on, and it’s just nice to be super busy and learn new things constantly.

Forging the Future & Clarifying the Complex in Custom Automation & Fabrication

Navus’ team is made up of hand-picked individuals who bring a variety of backgrounds and experiences to our work. We believe that a work environment like ours should be a safe place for our team members to show interest in new skills and grow in their career. Dedicated team members like David who have worked with us for so long are a part of the reason that our high standards for the solutions and products we deliver are possible!

If you’re interested in learning more about how we can help overcome your challenges through custom automation solutions, or if you’re interested in joining the Navus family, reach out to us today. You can contact us by emailing info@navusinc.com

Ryan is an Electrical Technician at Navus

The Team at Navus: Building Bigger & Better Machines

Navus

For over 20 years, Navus has built a reputation of building unique systems and machines that are cutting edge. It ultimately comes down to building bigger and better machines, no matter what changes in the world of technology. 

In our previous blog post, our team member Matt discussed how Navus is on the forefront of new technologies in custom automation. Part of the reason Navus is able to keep up with our ever-changing industry — and provide solutions that others haven’t thought of — is through the fresh perspectives of a younger generation of technicians and engineers joining the team.

Meet Ryan: Electrical Technician

Ryan R. joined the Navus team as an Electrical Technician at the beginning of 

March 2021. Trained as an Electrical Engineer, Ryan is excited for the opportunity to spend hands-on time building the panels he’ll one day be designing for Navus.

Hands-On Experience Adds to a Future in Engineering

Navus: Describe what you do in your role at Navus.

Ryan: I got hired as an electrical engineer, but at the moment I’m working as an electrical technician. I’m starting on the floor, learning how to assemble and wire control panels before I start designing them for projects. I’ve been wiring, cutting holes in panels for all the peripheral devices like air conditioning units, switches, all that kind of stuff. When I assume my full engineering role, I’ll have hands-on experience of what I’m developing and designing.

Navus: How did you end up in this career, and ultimately at Navus?

Ryan: Electrical engineering is a family tradition, all the way back to my great-grandfather. It’s what I was trained to do from a young age, and it’s the path I wanted to follow.

I got my job at Navus when I walked in with my resume! Bill Sauerhoefer came out and talked to me for about 15 minutes. I told him how interested I was in the company, and about a week later I got a call from Buck Barber, and then I started the interview process.

Navus: What’s your favorite part about your job and working at Navus?

Ryan: All of the hands-on experience I’m getting. Control systems engineers who work for larger companies sometimes never get their hands on the actual equipment. They never really learn about what they’re designing, which can cause a lot of miscommunication between the electrical technicians and the engineers. Navus is giving me that hands-on experience and putting me in the field so I can be an even more effective engineer one day.

A Team That Gets the Job Done

Navus: Describe some of the ways you’ve seen the team at Navus work together to overcome challenges.

Ryan: It was really awesome to see everyone come together on the runoff of a recent machine we built. We had the mechanical engineering team, electrical engineering team, welders, other vendors we were working with, all come together to make sure that this machine runoff went smoothly and was something we could confidently deliver to our client.

Navus: What do you hope for your future at Navus?

Ryan: I’m looking forward to assuming the responsibility of a formal electrical engineer, and managing the electrical engineering part of a project. In the future it would be amazing to manage the entire life cycle of a project. I’m looking forward to growing with the company and building bigger and better machines together.

Forging the Future & Clarifying the Complex of Custom Automation

Navus’ team is made up of hand-picked individuals who bring a variety of backgrounds and experiences to our work. We believe that a work environment like ours should be a safe place for our team members to show interest in new skills and grow in their career. Supporting team members like Ryan in their growing career is part of the reason that our high standards for the solutions and products we deliver are possible!

If you’re interested in learning more about how we can help overcome your challenges through custom automation solutions, or if you’re interested in joining the Navus family, reach out to us today. You can contact us by emailing info@navusinc.com.

[WHITE PAPER] Engineering The Future With Remotely Operated, Multi-Function Robotic Work Cells

Navus

Traditionally, adaptive welding robots have been used to handle low skill, repetitive tasks from a fixed location. But with the tools and features available today for offline programming, sensing, tool changing, and remote monitoring, robotic systems are gaining the flexibility and technology needed to widen the range of capabilities. This is particularly useful when the welding requirements involve extremely large metal parts located in a dangerous environment.

The unprecedented Navus system featured in this free white paper, Engineering The Future With Remotely Operated, Multi-Function Robotic Work Cells, moves the robotic welding workcell 100-feet into position in a dangerous environment while the operator works remotely from a safe location. The multi-task robot effectively preps joints, welds, provides inter-pass cleaning, and vacuums welds remotely.

By drastically reducing operator risk and increasing productivity with multi-function robotics, Navus’ system substantially reduces the prohibitive costs of time and expense of traditional methods required to achieve this vital task.

In the free white paper, you will see how this innovative robotic system:

  • Saves money and time by bringing weld cell to part.
  • Reduces safety risk of harsh work environment with remote operation.
  • Saves time by eliminating need for operator rotations every 15 minutes.
  • Reduces quality risks of weld inclusions with use of 1 operator.

To learn how this Navus system is forging the future for multi-task, remotely operated welds, read the free white paper, Engineering The Future With Remotely Operated, Multi-Function Robotic Work Cells, by clicking here to download

Founded in 1998, Navus Automation, Inc. is an industry leader in full-service custom machine building, welding, and integration solutions. We collaborate with many Fortune 500 companies in the automotive, military, agriculture, and consumer industries. Navus engineers provide exceptional robotic solutions for integrated systems that increase productivity, quality, and safety. Contact us online or call us toll free at 1 (866) 597-0750.

Navus To Speak at National Robotic Arc Welding Conference

Navus

Buck Barber, Sales & Marketing Manager for Navus Automation, Inc., will speak at the National Robotic Welding Conference & Exhibition (NRAWC) in Milwaukee on June 7, 2017. The conference highlights the newest tools and techniques for data driven, flexible robotic manufacturing.

Adaptive welding robots have traditionally been employed to handle low skill, repetitive tasks, from a fixed location. But with the tools and features available today for offline programming, sensing, tool changing, and remote monitoring, robotic systems are gaining the flexibility and technology needed to increase a single robot’s range of capabilities.

As an example of those advances in capabilities, Barber’s presentation at NRAWC will reveal how a remotely operated, multi-function robotic work cell makes welding in a dangerous environment more safe and efficient. The unprecedented system is designed to move the robotic welding work cell 100 feet into position in a dangerous environment while the operator works remotely from a safe location. The multi-task robot effectively preps joints, welds, provides inter-pass cleaning, and vacuums welds remotely.

Barber will be representing Navus as one of the featured industry leaders presenting on data driven flexible manufacturing with single or multiple robots, and new advances in optimizing upstream processes. This year marks the 34th anniversary of the conference. The mission of the conference has been to present new and emerging technology in the areas of welding and automation. The conference was unique from the beginning in that it did not have a call for papers but instead featured invited speakers, like Barber, based on cutting edge technologies.

With years of research and development and a certified weld inspector on staff, Navus has developed innovative strategies to meet the toughest challenges. Founded in 1998, Navus Automation, Inc. is an industry leader in full-service custom machine building, welding, and integration solutions. Navus collaborates with many Fortune 500 companies in the automotive, military, agriculture, and consumer industries. Navus engineers provide exceptional robotic solutions for integrated systems that increase productivity, quality, and safety.

 

Navus Obtains Versatile Waterjet Cutting Machine

Navus

The machine’s 5-axis motion allows for accurate bevel, arc, and angle cutting.

The team at Navus Automation, Inc., is one of the first in the region to acquire a Flow waterjet cutting machine. The CNC (computer numerically controlled) cutting technology uses high-pressure water jets as well as an abrasive to precisely cut through virtually any material, from paper or aluminum to steel or even granite.

The waterjet can cut material from 1/16 inch up to 10 inches thick, in high or low volume. A hair-thin pure waterjet stream is ideal for cutting soft materials, while a mixture of water and a garnet abrasive deftly cuts any hard material. The machine operates with a 5-axis motion for accurate bevel, arc, and compound angle cutting.

The cold cutting process means the materials are not subjected to the stress of heat or a heat affected zone. The cuts produce accurate and smooth edges, with minimal secondary finishing required. Waterjet cutting yields a tighter tolerance than plasma and oxy-fuel cutting, with less pre-cut preparation work and no post-cut grinding or deburring. Specifically, the technology allows for:

  • A traverse range of up to 500 in/min [12.7 m/min]
  • A linear straightness accuracy of +/- 0.0015 in/3 ft [+/- 0.038 mm/m]
  • Repeatability of +/- 0.002 in[+/- 0.050 mm]

With the acquisition of the Flow waterjet technology, Navus engineers are able to improve cutting accuracy and quality. The Flow software suite allows for quick and precise programming for cutting a part of any material and any thickness, widening Navus’ range of overall capabilities, efficiency, and productivity. Industries Navus will be able to utilize the waterjet cutting technology for include:

  • Aerospace
  • Automotive
  • Shipbuilding
  • Energy
  • Oil & Gas
  • Agriculture
  • Architecture

Founded in 1998, Navus Automation, Inc. is an industry leader in full-service custom machine building and integration solutions. We collaborate with many Fortune 500 companies in the medical, automotive, military, and consumer industries. Navus engineers provide exceptional robotic solutions for integrated systems that increase productivity, quality, and safety.

 

Automated Multipass Heavy-Deposition Robotic Welding

Navus

One of our major contracts required welding large steel sheets for shipbuilding, which is typically a time-consuming endeavor, especially considering that the parts can weigh as much as 30 tons. However, with a multipass high-deposition robotic welding technique we were able to reduce the overall process time by about 60%.

Six ABB IRB 4600 robots, three on each side of the cell mounted on 30-meter tracks, move along using a Fronius GP tandem system. The robots work within two cells to achieve interpass cleaning, grinding, and removal of any silicate that could compromise finish quality.

The workpiece is a 2”-thick steel plate that must be flipped a total of four times for the completion of welding and cleaning between each pass. The welds require an interpass temperature of 200-300ºC, and cleaning must be completed before each pass.

Our engineers used RobotStudio to program the parts offline based on our client’s modeling software. Digital manufacturing with offline programming is essential in achieving a project of this scale.

With this system, our client was able to cut their manufacturing process from a minimum of 28 weeks to eight weeks for one key component, which reduces the overall build time per set of components by approximately 60-70%. Best of all, the increased productivity doesn’t come with any costs in quality. The robotic system has been qualified to complete UT (ultrasonic testing) class welds.

This project has been key to reaffirming our reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions.

Founded in 1998, Navus Automation, Inc. is an industry leader in full-service custom machine building and integration solutions. We collaborate with many Fortune 500 companies in the medical, automotive, military, and consumer industries. Navus engineers provide exceptional robotic solutions for integrated systems that increase productivity, quality, and safety.

 

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