Medium Industry
November 19, 2020

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

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Light Industry
October 29, 2020

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.

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Custom Automation
October 15, 2020

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.

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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.

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Heavy Industry
October 1, 2020

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!

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Medium Industry
September 24, 2020

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!

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Light Industry
September 10, 2020

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!

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Company News Robotic Work Cells
July 27, 2017

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

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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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Welding
July 10, 2017

Navus Fills Niche For Adaptive Multipass Welding

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Navus

A crystal clear image from the HD camera during inspection shows 0 inclusions.

Here at Navus, multipass adaptive welding is one of our signature strengths. Having an adaptive process for welding allows us to create higher-quality joints on even the heaviest pieces. Our process has even been successful on joints with over 60 passes.

As Buck Barber, Navus’ General Manager explains:

“The team developed an algorithm that allows the system to adapt to changing joint parameters including width, position, and angle. In a sense, this allows us to hit a moving target. No one has put the technology together to do it quite this way.”

The resulting welding process is quicker, more consistent, and of higher quality.

What Is Multipass Welding?

As the name implies, multipass welding involves making multiple passes in order to weld a joint. However, this type of weld isn’t typically used for every joint you want to make. Instead, it’s reserved for when you have thick sections that need to be welded together. 

It’s also useful for:

  • Making repairs
  • Build ups
  • Surface hardfacing

Another important aspect to note is how often welds are made during this process. It’s usually best to let a weld cool after one pass before making another. 

 

Click here to download our latest white paper on increasing your productivity with new weld technology!

 

Implementing Automated Multipass Robotic Welding

Multipass welding can be a time-consuming project, especially in heavy industries. Fortunately, automated processes can help cut down on time. As one of our major clients who use parts weighing as much as 30 tons discovered, our automated systems can cut down on time by around 60%.

For this client, we used six ABB IRB 4600 robots. With three positioned on each side of the workcell and mounted on 30-meter racks, the Fronius GP tandem system makes the final touch for extremely heavy parts. 

We split the robots into two cells, working to perform tasks such as interpass:

  • Cleaning
  • Grinding
  • Removal of impurities that could affect the quality

The system is capable of maneuvering 2-inch steel plates that need to flip four times to complete the welding. The welds must reach an interpass temperature of 200-300ºC, as well as be cleaned between each pass. 

Our client provided information with their modeling software, allowing our engineers to program the parts offline using RobotStudio. This method is essential in order to achieve a project of this magnitude.

In the end, we were able to develop a system that cut our client’s manufacturing process from 28 weeks to eight. This is especially important since it involves creating one of their key components, which also drastically improves their output without any cost in quality. 

 

Click here to read more about this project!  

 

Adaptive robotic welding solutions like these are important for improving consistency and speed. Due to safety regulations, operators are given only a short period of time to work. If an operator has to switch every 15 minutes because of dangerous conditions, a wide gap is created where no value is being generated for the product. With robotics, these gaps are filled and arc-on time is maximized.

Strict ultrasonic testing requirements are needed since testing can’t be completed until the entire joint is finished. Any inclusion found in the root pass will result in the entire welding being ground out in order to be repaired. With automated multipass robotic welding, these occurrences are minimized while higher speeds allow the process to recover more quickly.

Navus — Providing Innovation in Automated Welding Since 1998

At Navus, we have years of experience with research and development as well as an on-staff weld inspector. This helps us to develop innovative solutions to solve the toughest challenges in welding. Whether you need to be able to weld in all positions, welds that stand up to the most rigorous testing, or both, we have the knowledge and experience to create a process for you.

Our solutions for multipass heavy deposition robotics include:

  • A portable robotic work cell for multiple welds in multiple positions
  • Robotic tool changes for single-torch welding, grinding, deburring, and cleaning
  • Remote operating solutions for hazardous environments to prep joints, weld, clean, and inspect
  • A T-beam welding robotic cell that reduces production time by nearly 70%
  • A custom weld cell with six robots to weld and clean odd-shaped 30-ton parts

Are you interested in how Navus can help with your automated welding needs? Contact us today to learn more!

 

Multipass adaptive welding is one of our signature strengths here at Navus. We have developed an algorithm that allows the system to adapt to changing parameters including angle, width, and position. This allows us to create processes for heavy-industry clients using parts as heavy as 30 tons, cutting down on time by around 60%.

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.

 

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Company News Events & Trade Shows Welding
June 5, 2017

Navus To Speak at National Robotic Arc Welding Conference

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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.

 

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Company News
May 11, 2017

Navus Obtains Versatile Waterjet Cutting Machine

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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.

 

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The employees of NAVUS Automation utilize technology and innovation to make our customers more productive, safer and to make their companies more profitable. These are the standards we will use to measure the quality of our efforts and provide for continual improvement.

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NAVUS Automation Inc.
2640 Westcott Blvd.
Knoxville, Tennessee 37931
United States

Telephone: +1 865 692 8443
Fax: +1 865 692 8440
info@navusauto.com

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