Sensor-Guided Robotics Handling Multi-Ton Parts?

Not All Integrators Are The Same: How Navus Saw What Others Couldn’t

Navus

We don’t have to tell you about the challenges and complexity of making the different systems in your facility communicate and work together. If you find managing line production day-to-day feels more like a nightmare than the smooth process it should be, you may be partnered with the wrong automation integrator. Choosing the right automation integrators makes all the difference in how well your systems run, their impact on your day, and the future growth of your company.

No matter what challenge you’re facing in your manufacturing facility, different automation integrators will always come up with different ways to resolve your challenges. When choosing a partner, it comes down to choosing the smartest solution possible for your company. Integration isn’t just about solving your current challenge, it’s also about looking to the future and seeing possibilities for the success of your business that your current integration partner may not have considered. 

Our team at Navus has proven our ability to stand out above other integrators with our knack for seeing what others didn’t, and applying ingenuity to not only solve immediate complex challenges for our clients, but also to think towards the future and how our turn-key systems can provide intelligent solutions that consider future challenges your company may face. In this blog series we explore how the work that we’ve done sets Navus apart from other integrators.

Sensor-Guided Robotics Handling Multi-Ton Parts?

A couple of years ago we gained a client in a nontraditional way because of our ability to think of the smartest way to solve challenges. Their facility manufactured multi-ton parts, and they wanted to automate a part of the process that had historically been done manually by employees. They required a machine that could automatically locate and identify one of their heavy parts by recognizing its shape and features, create a tool path for the part, and mill all sharp edges to a close-tolerance radius, all while ensuring downstream processing success using robotic programming. 

Our client hired a different integration team before they approached us, but the system that their first integration partner engineered failed when it actually came to programming a robot to locate and identify each part before milling the sharp edges. Our client recognized that this was a central part of the solution they needed, and reached out to us for a second opinion. Our entire team was confident we could engineer a solution and we put our heads together to figure out how to accomplish what seemed impossible to accomplish.

How Did We Do It?

Whatever system and machine we developed needed to account for fluctuation in size and weight of our client’s manufactured parts. Part positioning tolerances and dimensional variations can decrease productivity, causing high rejection rates and downtime in industrial robotic applications, and we wanted to avoid those roadblocks at all cost. Our machine needed to consistently deliver a part at the end of the tool path that has been measured with all sharp edges milled into a precise radius in less than an hour from start to finish, with no need for manual manipulation.

Robotics were our best friend when it came to solving this particular challenge. Our team utilized experience and ingenuity to create a system that could: 

  1. Find and measure a particular part
  2. Write a program for itself based on the position of the edges of the part
  3. Automatically grind edges to a precise radius 

The result of our ingenuity was a multi-faceted machine that accomplished all of our client’s intended goals. The process we engineered utilized sensor guided robotics, automatic tool path generation from sensor inputs, automatic robot program generation, and custom designed material handling equipment to reliably move and precisely position very heavy materials. Our clients required the process to take under an hour in order to be more efficient, and our machine accomplished the entire process beginning to end in only 25 minutes. 

Our team’s ability to think outside of the norm for robotics and programming solved a problem that seemed nearly impossible for our client. We took what other automation integrators failed at and turned it into a solution that went above and beyond what our client expected. Read more of the specifics about how we solved their challenges by downloading our recent white paper.

Why Are Navus’ Solutions Smarter Than Other Automation Integrators’ Solutions?

It all comes down to our team at Navus. Every one of our engineers is passionate about solving specific challenges for every single one of our clients who partners with us. Our experience, ability to think outside of the box, and passion make all of the difference in ensuring our turn-key system solutions accomplish what other automation integrators can’t. Partnering with Navus isn’t just about figuring out a solution for your current challenges. With every client we partner with, we promise to bring new ideas and solutions to the table that create future possibilities for your manufacturing space, and the future growth of your company. 

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.

For more information on how our team can help you solve complex challenges in your manufacturing facility, reach out to us today!

Why Are Navus’ Solutions Smarter Than Other Automation Integrators’ Solutions?

Not All Automation Integrators Are The Same: How Navus Engineered What Didn’t Exist

Navus

We don’t have to tell you about the challenges and complexity of making the different systems in your facility communicate and work together. If you find managing line production day-to-day feels more like a nightmare than the smooth process it should be, you may be partnered with the wrong automation integrator. Choosing the right automation integrators makes all the difference in how well your systems run, their impact on your day, and the future growth of your company.

No matter what challenge you’re facing in your manufacturing facility, different automation integrators will always come up with different ways to resolve your challenges. When choosing a partner, it comes down to choosing the smartest solution possible for your company. Integration isn’t just about solving your current challenge, it’s also about looking to the future and seeing possibilities for the success of your business that your current integration partner may not have considered. 

Our team at Navus has proven our ability to stand out above other integrators with our knack for seeing what others didn’t, and applying ingenuity to not only solve immediate complex challenges for our clients, but also to think towards the future and how our turn-key systems can provide intelligent solutions that consider future challenges your company may face. In this blog series we explore how the work that we’ve done sets Navus apart from other integrators.

Seamless Integration & No Line Layout Changes

One of the most unique client challenges we’ve helped resolve to date was a modular machine for the assembly of small parts. The machine needed to handle a 26-step manufacturing process contained in the single, modular machine. Our client had pre-existing systems that built these particular parts in their manufacturing facility, but the legacy systems were not able to produce fast enough to meet the demanded volume of manufactured products. They needed additional systems to decrease production time for orders that followed the same general manufacturing steps, but that could be contained within a small footprint of the manufacturing floor. 

The system that Navus proposed did more than just solve our client’s initial challenge. It opened up a new world of possibilities for the future of their manufacturing facility and production times that translates directly to the growth of their business.

The end result of this project was a machine that assembled parts faster than our client could have imagined, without taking up extra space on the manufacturing floor. The design and programming of the machine itself created a platform for which all of their future line layout can be accomplished without the need to change manufacturing floor space requirements—and in fact, free up more manufacturing floor space to include new lines as their business grows.

How Did We Do It?

One of our client’s main goals was to utilize automation to achieve a faster production time. The goal for each part of the automation process was to be completed under 2.5 seconds. But the automation system had to be flexible in order to account for multiple variations in the product. On top of this, our client wanted to affordably automate the assembly process inline with existing equipment without changing their facility’s floor plan.

For this system’s automation application, we needed to create a machine cased within a custom safety enclosure that also featured an in-feed conveyor system with part escapements, a label application system, a height inspection sensor, nail feeding and insertion systems, a part nest tooling system, an operator control panel, and an out-feed conveyor system.  

We did it all with the use of a flexible robotic automation process contained within one modular machine. 

Instead of the traditional approach of using multiple robots programmed for different steps of the assembly process down a long assembly line, our engineers’ solution used a robot’s ability to do multiple functions in the assembly process to make our client’s desires a reality.

The turn-key systems solution we designed:

  • Automated the label application process
  • Inspects and verifies the height of certain parts
  • Feeds nails into the correct spot
  • Nests boxes together
  • Provides a robotic quality check (and disposes of faulty parts)
  • All contained in one modular machine that took up minimal floor space in our client’s facility

The result? With this new process, our client was able to produce 24 individual, finished parts within one minute, increasing their capacity for production without the need to change manufacturing floor space requirements. For more details about this particular project, check out our recent visual case study!

Why Are Navus’ Solutions Smarter Than Other Automation Integrators’ Solutions?

It all comes down to our team at Navus. Every one of our engineers is passionate about solving specific challenges for every single one of our clients who partners with us. Our experience, ability to think outside of the box, and passion make all of the difference in ensuring our turn-key system solutions accomplish what other automation integrators can’t. Partnering with Navus isn’t just about figuring out a solution for your current challenges. With every client we partner with, we promise to bring new ideas and solutions to the table that create future possibilities for your manufacturing space, and the future growth of your company. 

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.

For more information on how our team can help you solve complex challenges in your manufacturing facility, reach out to us today!

White Paper: Making the Impossible Possible with Sensor-Guided Robotics

Navus

Navus has always been known for our ground-breaking welding work, but did you know that we specialize in a range of industry-specific custom automation? Over the years we’ve helped countless clients realize the potential for their business to grow faster and stronger through automated processes. In heavy-industry manufacturing, custom automation can be especially beneficial. 

White Paper: Transforming Medium-Industry Manufacturing Through Vision-Guided Robotics and CAD to Path Generation

Navus

Automation using robotics isn’t a new concept in the world of manufacturing, but many industries are still discovering robotics’ endless possibilities. Medium-industry manufacturing is associated with automotive, aluminum die casting, and durable goods, but residential construction falls into the same category. Building a prefabricated residential structure may seem like it’s a heavy-industry project, but it’s really a lot of medium-industry pieces combined to create one finished product, much like a car.

The latest free white paper we’ve published features a medium-industry project that introduced automation to the featured clients’ facility. Our client had historically had their employees manually measure and cut all of the floorboards needed for a prefabricated residential building. The issue with a manual process lies in the room for human error. Each floorboard piece had different required measurements in order to match the layout of multiple building plans. Employees at their manufacturing facility measured, cut, and organized each floorboard with their own hands. Our clients knew there had to be a more efficient and precise way to complete this part of their process.

Our engineers are always excited to design a new process for a client, but this project was particularly exciting. Our clients had no other automated processes within their facilities. The process our engineers designed would be the first for the entire company. 

Our clients needed a process that could translate building plans from two dimensional CAD drawings to finished floorboards, cut, stacked, and organized in order of their use in the downstream process. The automated system required vision-guided robotics, custom software, and adaptability with minimal input from an operator.

Though the project seemed complicated, our engineering team knew they could design a system that met all of our clients’ needs, as well as delivering faster production times and decreased safety risks for employees within their facility. The result of our engineers’ expertise was an easy-to-use-system that integrated with their other processes to deliver finished products faster than they thought possible.

In this free white paper, you’ll discover how this custom, adaptable system:

  • Decreases safety risks to employees through remote operation
  • Creates more revenue through increased throughput
  • Saves time and money through decreased production time
  • Eliminates the possibility of human errors with precise measurements translated with robotics and custom software to result in cut, organized floorboards

To discover more about how Navus engineers used vision-guided robotics to design a custom automation process that worked for our client’s needs, you can read all about it in the free white paper, Transforming Medium-Industry Manufacturing Through Vision-Guided Robotics and CAD to Path Generation.

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

DOWNLOAD NOW

Visual Case Study: Custom Automation for Dynamic Productivity in Light Industrial Manufacturing

Navus

At NAVUS we develop and design projects of all scales and levels. Sometimes the projects we do are focused on achieving a process design that seemed impossible for our clients due to complexity or scale. Our engineers excel at tasks and projects that take a complicated process and streamline it to suit your company’s needs. 

Recently we acquired a client that already had automated processes within their facility for the production of a particular product, however, their downstream process required these products to change orientation in order to be packaged correctly without associate intervention. Our engineers were given specific goals, materials, and space to work with in order to create the custom automated process and integrate it with existing processes within our client’s manufacturing facility. Not only did we have very specific parameters, but the product itself was complicated. Our client needed assembly of multiple components to be accomplished within the space they dedicated to our process. The finished process would have to be dynamic in multiple ways.

To complete this project, our engineers needed to:

  • Design an automated process that integrated with existing processes within our client’s manufacturing facility
  • Keep the footprint of the process small, meaning multiple stages of assembly had to happen in the same process enclosure
  • Ensure that the process could nest multiple parts precisely together to comply with downstream packaging systems

The finished process was proposed to produce 24 parts per minute with the supervision of only one operator. These specific guidelines and requests from our client were definitely different from the projects we typically highlight:

  • The scale of the product itself is smaller than the products and parts we typically engineer custom automation processes for
  • The variables we had to keep in mind while designing and engineering the process made it a much more complex project
  • The finished process needed to work with other processes in the facility, but we could still make it something completely unique for our client

All of the variables and complexity presented an intriguing and unique project for our engineers to navigate. Together with our valuable vendors, we designed an automated process that worked and looked more refined than our clients could have imagined. To discover more about how Navus engineers used robotics to design a custom automation process that worked for our client’s needs, you can experience it all through our free visual case study, Custom Automation for Dynamic Productivity in Light Industrial Manufacturing, by clicking here to download.

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.

DOWNLOAD NOW

The Easy 5-Step Transition to Custom Automation and a Profitable Future

Navus

Just because you’ve done things manually in your facility for years doesn’t mean you can’t transition to a faster, easier process. Transforming the processes in your facility is a big decision, but maybe you’ve already done your research on custom automation and integration. Maybe you’ve read our case studies and white papers on how engineered automation can benefit you and your industry. Maybe you’ve even considered the ROI and found it to be worth pursuing. But now what? What are the first steps in the transition to integrating a custom automation process designed specifically for your product and your facility?

The actual transition sounds complicated and hard, but it doesn’t have to be. Partnering with NAVUS to create a customized automation solution that integrates seamlessly in your facility for your specific needs is a great way to ensure a smooth transition and a profitable future. Simply put, we take the complication out of automation. We’ve outlined the simple 5-step process that we follow when helping a company embrace its full potential through implementing a custom automation process into their manufacturing facility.

1. Share Your Vision With Us

The first step in any project we undertake is to discuss in detail with prospective clients what their highest hopes and dreams are for their manufacturing facility. We have helped countless clients achieve what they thought was impossible, but the first step in a fruitful partnership with NAVUS is to let us into your world and all that you imagine it can be.

We can schedule a time to tour your facility with you so we can see the current processes you have in action. During this part of the process, our engineers take notes as to how we can utilize what’s already existing within your facility to design something new and improved. This is also an excellent time to show us what you want to keep and what you don’t mind changing. Our engineers walk away from this facility tour with their mind already buzzing with possible options to improve production in your facility.

2. Propose the Possibilities

After discussing your goals with you and your team and touring your facility, NAVUS’ team of engineers compile a list of possible solutions for you to review. Whether we design multiple processes for your facility, or only tackle one at a time, nothing makes it into the prototype or production stage without your approval. 

All of our ideas and proposals are focused on increasing production, streamlining consistent quality, and maximizing revenue. We won’t propose an idea that doesn’t have your company’s best interest at heart. 

Once your team has reviewed the possible solutions, we can get together again and discuss what the next steps look like for our partnership. Our goal is not merely to solve your manufacturing problems through custom automation and integration. We want to do it in a way that works for your needs and emphasizes your success

3. Design & Development

The design and development stage of custom automation and integration is no doubt one of the most exciting steps. In this stage, NAVUS engineers combine concepts and reality to fully design the processes that have only existed in their imagination so far. This is an opportunity for our engineers’ experience and wisdom to shine when showing you the possibilities of what they’ve already proposed. 

Paying attention to detail in the design and development process allows for us to make sure every variable has been considered before building your custom process. Many of our proposed system designs are put through extensive simulation and demonstration processes. The simulation step confirms that our proposed system design is feasible before starting to cut, weld, and fabricate the parts to build it. We can also use our in-house robots and automation technologies to bring these simulated versions of your process to life through scaled demonstrations in our shop, known as a “Proof of Concept”. During a proof of concept demonstration you’ll get to see the process in action before we build the final version that will live in your manufacturing facility 24/7. This gives you the opportunity to fully analyze any risks and rewards before moving forward in the process.

4. Building Your Custom Automation Process

Once we’re confident that your custom automation process will do everything you want it to, we begin building the system in our manufacturing facility. Every process we design and build becomes reality on our shop floor in Knoxville, TN. We partner with some of the best vendors in the business to provide you with a process that will last you a lifetime. Once all of the pieces are brought together to create the cohesive system, we extensively test the system to ensure it  performs the way it is designed to.

When it has passed all of our tests and has a consistent performance, we get it ready for integration into your manufacturing facility!

5. Integration

After your custom automation process has been completed and approved by you and your team, we move onto the integration portion of our partnership. We fully supervise every step of the process. We ensure that the installation process is thorough and fast, with minimal downtime for your facility. 

We also make sure that you and your team are completely trained on how to optimally use your new process. Our partnership doesn’t end with installation. When NAVUS designs a custom automation process, they follow through, even beyond integration and training. If you ever have a concern or question regarding the possibilities of your automation process, our team of engineers is eager and available to speak with you. 

Wrapping Up

Custom automation and integration isn’t a new concept, and it’s not going to go away anytime soon. In order to keep up with modern manufacturing, facilities have to consider automation and integration at some point. The question eventually comes down to, ‘Who will you hire?’ NAVUS is dedicated to discovering the best way to make your business thrive through custom automation and integration. Our passion for automation in manufacturing isn’t simply because we’re the best. It’s because we want you to be the best. 

If you’re ready to discuss how NAVUS can help you and your business move forward from outdated production practices and embrace the future of manufacturing, reach out to us today! Our team of engineers is ready to help you take a step forward into the future by making the impossible possible for you and your entire company.

GET STARTED TODAY

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.

Feature Project: Custom Robotics Automation Processes in Heavy Industry

Navus

One of the things we pride ourselves on at Navus is our ability to help our clients realize the potential for their business to grow faster and stronger through custom automation in their manufacturing facilities. This year we published a feature project that is the perfect example of this.

The Manufacturing Challenge

The client featured in this project handles parts that are multiple tons in their manufacturing facility. The manufacturing process was still manually completed by associates in their facility using heavy and sharp grinding tools. They simply needed a new custom automation process that would minimize manual manipulation from associates, and create faster production times.

The Automated Solution

This new custom automation process:

  • Increased throughput through faster production times
  • Promised consistent quality-assurance
  • Minimized the need for employees to manually complete the process

Discover more about this project!

The finished process gave our client even better results than they had dreamed or asked for. Navus Automation Inc. specializes in making the impossible, possible. 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.

Get Started Today!

Feature Project: CAD Translation Using Vision-Guided Robotics

Navus

Medium industrial manufacturing includes projects of all shapes and sizes. From automotive to construction, medium industry manufacturers have a diverse range of production needs. This is why Navus has created a reputation for troubleshooting and envisioning exactly what your facility needs when it comes to a custom automation process. 

The Manufacturing Challenge

In one of our recent feature projects, the client needed something created from nothing. Every process in their manufacturing facility was being done manually. From the most important tasks, to the smallest ones, and everything in between. In order to start a gradual change towards automated processes, our client chose one manual process to replace. The challenge? Their new process needed to translate CAD to path generation using vision-guided robotics.

The Automated Solution

The new automated process our engineers created:

  • Decreased safety risks to employees 
  • Saved time and money for our clients
  • Increased throughput, allowing for higher revenue

Discover more about this project!

The finished process gave our client even better results than they had dreamed or asked for. Navus Automation Inc. specializes in making the impossible, possible. 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.

Get Started Today!

Feature Project: A Dynamic, Custom Process for Light Industry Manufacturing

Navus

Automation in manufacturing can involve parts that are multiple tons, but also parts that are smaller and more focused on consumer-based products. Think about it. Any small item you can find in large quantities in a chain store has to be mass-produced somehow. While Navus usually specializes in helping manufacturers in medium and heavy industries, that isn’t always the case.

The Manufacturing Challenge

One of our recently featured projects is all about how we helped a client by engineering a custom automation process built with dynamic productivity in mind. They already had a pre-existing process in a specified space in their facility. Our engineers had precise parameters to keep in mind, both in regard to the facility space and the pre-existing process.

The Automated Solution

Our engineers had to:

  • Engineer a new, dynamic, custom automation process that would integrate with pre-existing processes
  • Design a way for multiple steps of the new process to happen in the same space to keep the footprint small
  • Make sure the new process that did multiple steps in the same space also correctly puts small parts together with minimal input from associates

Discover more about this project!

The finished process gave our clients even better results than they had dreamed or asked for. Navus Automation Inc. specializes in making the impossible, possible. 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.

Get Started Today!

[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.

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