Category: Industry News

Workforce Automation and Robots

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FANUC Robotics

Workforce Automation and Robots

Automation has been in mind for not just decades, but centuries. Whether we’re talking about those who worked in flour mills or those who dealt with windmills, automated processes have always been on inventors’ minds. While automation would technically result in job losses, the increased prevalence of robots and robotics parts (FANUC Robotic Parts found at MRO Electric)  in the manufacturing, packaging, and engineering space would result in interesting implications for consumers, employees, companies, organizations, etc.

Does Workforce Automation Result in Job Losses?

Many are convinced that automation will come and take over a majority of the work done by humans in the next few decades, and some feel as though their jobs are safe. Let us take China for example. China is one of the most dominant manufacturing hubs in the world, supplying a huge chunk of the world’s electronics products. Over the past few years, Chinas’ factories cut human workforce by an astounding average of 50%, due to the increased prevalence of robots.

Are there Advantages of Workforce Automation?

Although there is definitely a negative side of workforce automation, do positive sides exist? Customers could experience, to an extent, cheaper and more effective services and products. This would be due to the cost savings of the autonomous robotics, which yield a one-time fee along with other basic upkeep costs. Lower production costs would also make it possible to build items in the U.S. vs overseas, which many would prefer.

 Automation Limits?

There are limits to mostly everything, and automation is no exception. Short product life cycles that quickly become obsolete and ability to entertain fully-custom projects do not fit into an automation system. For example, paying for a large number of robots to build an electronic product that will become obsolete in less than a year would not be a smart decision from a business standpoint. The ability to be flexible and custom is imperative when concerning several products in several different markets.

What does Second Machine Age Mean?

Robotics in machine automation is becoming a larger part of the workforce as time goes on. Some companies plan to simply increase production levels with the help of robots and robotics parts while keeping their employee count the same and reassigning their workers to other positions within the company. With the addition of robots and robotic parts in the workplace, workers will be needed to maintain robots, calibrate and monitor them, analyze data and more.

The rise of robots and robotic parts is unavoidable in several niches. Today’s technological prosperity is changing tomorrow’s workforce for good. MRO Electric and Supply has new and refurbished FANUC Robotics parts available. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.

Lastly, be sure to check out our articles on boosting factory automation productivity here.

Siemens’ Update Broadens Toolset for Digitization in Machine Shop Environments

Joe Kaminski Leave a comment

Siemens CNC

Siemens’ Update Broadens Toolset for Digitization in Machine Shop Environments

The most recent update from Siemens’ NX software coalesces the next generation of tools concerning additive manufacturing, CNC (computer numeric control) machining, robotics, and, last but not least, quality inspection to enable the digitalization of part manufacturing within a single, cohesive end-to-end system.

Up-to-date automation competence for computer-aided manufacturing (CAM), including robotic programming, adaptive milling, and tooling design, provide innovative, industry-specific technology to help deliver high-quality products to the market in less time. The new NX Machining Line Planner tool, combined with integrated NX CAM software for feature-based machining, provides new capabilities for industries with high-volume production of complicated parts, such as automotive and industrial machinery. The latest version of NX continues to support end-to-end solutions for additive manufacturing, helping manufacturers realize the goal of using 3D printing for industrial production.

Part manufacturers proceed to face increased pressures from modified market expectations, with customers who require optimized accuracy and faster response times. In order to remain competitive, many part manufacturers look to digitalization, which connects all of the steps of part manufacturing planning and production with a single source of information, or a digital thread. Implementing a digital strategy can enable part manufacturers of all sizes to take greater advantage of automation, adopt 3D printing for production, and ultimately expand into new market opportunities and reduce time to delivery.

State-of-the-art automation enhancements within the latest version of NX provide powerful ways to expand production efficiency and decrease cost. Robotic programming technology provides the ability to automate complete manufacturing cells, including programming robots to perform machining. Adaptive milling and tube milling are new capabilities that provide innovative ways to automate CNC machines and accelerate cutting of complex parts. Adaptive milling is a high-speed cutting method that leverages automation within NX to decrease machining cycles by up to 60 percent while extending tool life. Tube milling streamlines the 5-axis programming process by eliminating preparation and minimizing inputs, utilizing advanced capabilities to create ideal tool paths and minimize errors in machining on the shop floor.

Mold and die manufacturers can now accordingly dictate tool production costs through integration between NX and the Teamcenter portfolio. Engineers can now use NX to automatically recognize features and parameters on the desired part, and provide pertinent information to Teamcenter, which can precisely calculate the tool cost. The newly integrated capabilities of Siemens’ product lifecycle management (PLM) software solutions can enable tool manufacturers to win more orders and increase profit margins through automated costing and accurate quotations.

New to this version, NX Machining Line Planner, combined with integrated NX CAM, enables the feature recognition, distribution, balancing, programming and simulation of operations over multiple setups and machines. Particularly helpful for industries with high-volume production of complicated parts with many features, NX Machining Line Planner uses a digital twin of the complete machining line and NX CAM feature-based machining technology to optimize the entire process. NX Machining Line Planner, combined with the power of the digital twin, offers a truly unique solution that enables automotive and machinery manufacturers to reduce planning time and increase overall production results.

The newest version also inflates the new additive manufacturing solution in NX by including the new module, NX AM for HP Multi Jet Fusion, which is certified by HP and powered by Materialise, to prepare print jobs for HP Jet Fusion 4200 3D printers. The NX software module will allow customers to develop and manage parts in a single software environment for Multi Jet Fusion printing solutions, avoid costly and time-consuming data conversions and third-party tools, and improve their overall design-to-finished-part workflow efficiency.

Additionally, Siemens develops applications for additive manufacturing process simulation in Simcenter 3D, a crucial tool to help manufacturers industrialize additive manufacturing by printing components the first-time-right. These simulation applications are an integral part of the Siemens’  additive manufacturing solution. Increasing productivity is one goal for most of those in the automation space (check out boosting factory automation productivity here). MRO Electric and Supply has new and refurbished Siemens products available. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.

IT and Robotics

Joe Kaminski Leave a comment

Information Technology involves storing, retrieving, altering and transmitting massive amounts of data.

Because IT is heavily reliant on computers, automating the field is definitely the most practical direction.

Slowly taking rein in the sector, RPA (Robotic Process Automation) is terminating the manual effort associated with IT tasks and business processes.

RPA grips technologies such as AI (artificial intelligence), machine learning and vision, big data analytics and, eventually, quantum mechanics, to complete several tasks.

There are two types of automated deployments:

  1. Simplified robots (such as FANUC Robotics products found here) that execute a script to recurrently execute a specific function.
  2. Cognitive RPA/software-based AI that learns the tasks they are presented with and learn how to make choices on their own.

Currently, large global IT and BPO (business process outsourcing) organizations are using lesser forms of RPA.

Using RPA enables organizations to provide IT services at higher efficiencies and minimize costs.

Utilizing RPA enables organizations to provide IT services at increased efficiencies while cutting costs.

Many say that a handful of companies are currently in the early stages of conducting RPA proof-of-concept trials, while some are entertaining production pilots.

Affected Areas

Many IT service lines are expected to come under RPA’s influence.

  1. Helpdesk is a field that falls under this category. RPAs could potentially automate non-ticketing activities that, as per IT reports, occupy 25% to 40% of a helpdesk’s tasks. Some of these tasks include monitoring, providing clarifications and reporting. As for ticketing, RPA could assist in automation common service requests such as password resets.
  1. IT infrastructure outsourcing is another area that is expected to be impacted by RPA. In this, robots (such as FANUC motors, amplifiers, and drives) could observe critical thresholds and, under certain threshold breach conditions, could even fix the issue.

Companies have already started to leverage RPA for many of their client projects.

Processes that mandate RPA include rule-based, high volume, several systems, repetitive tasks, data mining, or data entry tasks. MRO Electric and Supply has new and refurbished FANUC Robotics products available. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.

Automation Advantages

  1. RPA slashes labor costs immensely.
  2. The technology offers a less prying way for integrating systems because software AI access applications through the user interface.
  3. Robots would connect to various UIs, including legacy green-screen applications, and would not touch the underlying software.
  4. RPA projects require less time and money when compared to traditional automation.
  5. AI robots will provide better quality, faster processing times (within hours compared to weeks with manual approach), major improvement in traceability for audit purposes, and increased high-speed analytics.
  6. RPA would easily scale and address fluctuations in volume.

Feasibility

Automation projects, as per industry experts, should not take more than a year to complete. They would likely cost between half a million USDs to two million or more, depending on the number of robots and their complexities. Check out our article on factory automation and machine-to-machine learning here.

Control Market & Industrial Automation Trends

Joe Kaminski Leave a comment

Control Market & Industrial Automation Trends

Industrial Automation

Vendors Will Need to Advocate Portable Applications

The lack of multivendor portability of applications is an enormous issue for those in the automation industry. The operators behind the automation architecture initiatives understand that without open ecosystems, providing portable applications between vendor platforms, revolution is stifled.  Nontraditional suppliers are already offering products that are programmed with IoT software.

Edge Devices Will Blossom

The rapid rise of the Internet of Things concepts and technologies, including high power/low-cost processing and communications technologies, is enabling new intelligent nodes, which operate at the network edge to improve manufacturing performance and efficiency. This will be a growing trend.

The quick rise of the Internet of Things ideas and technologies is empowering state-of-the-art knowledgable nodes, which operate at the network edge to polish manufacturing performance and efficiency.

Omnipresent Smart Sensors

Smart sensors and control devices have been proven to produce aid by yielding increasing amounts of contextual data. Because of the most recent IO-Link addition gaining quick adoption, the cost of implementing smart sensors has decreased immensely. Along with these are Ethernet sensors. Ethernet sensors communicate using industrial and related formalities, which contribute data for automation and communicate directly with business systems. Industrial applications have also begun to use Bluetooth sensors.

Collaborative Robots Will Become More Affordable

As many of us know, the number of collaborative robots dramatically increased in 2016. These newly-established light and inexpensive robots are engineered to operate cooperatively with people. They are also intended to incorporate vision systems along with state-of-the-art software to provide self-awareness. These robots have average costs of under $40,000.00, making them suitable for an enlarged number of tasks. These robots are evolving similarly to how personal computers have- providing a product with less power than larger offerings, but adds value for a larger number of users.

Internet of Things (IoT) Technology Will Slash Automation Costs

Talk of the Internet of Things (IoT) theories, and the technology influencing the industry is starting to feel very real. The progressing maturation of technology and merchandise is stimulating the Internet of Things with fastened innovations including higher-powered processors, analytic software, sensors, cloud computing, visionary systems, and more. All and all, this will likely result in more economical and higher performing industrial automation systems.

Thinner Architecture Will Come to Automation

As many professionals in the industrial automation space know, 2-3 layer automation systems are beginning to occur, resulting in increased performance and less software maintenance prices. This trend is becoming more and more common, with computing being driven down into more handy controllers, intuitive instruments, and driven up to plant level computers and cloud-hosted applications.

MRO Electric and Supply has new and refurbished products available. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.

fanuc repair

Automation Cleanup Procedures for Flood Damages in TX & LA

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Automation Cleanup Procedures for Flood Damages in TX & LA

MRO Electric is determined to provide the best service and support to businesses affected by Hurricane Harvey during these difficult times as they resume operation and employees get back to work.

Water-immersed electronic devices and motors in automation systems need appropriate treatment after flood water subsides. We have compiled information we learned from our past flood relief activities below, which we think our customers affected by Harvey may find useful.

We also have the capability to wash and test the amplifiers and printed circuit boards at our repair facilities.

Recovering Industrial Electronics from Flood Damage

If the CNC and related equipment are treated properly after being soaked with flood water, it is possible to reduce or even recover from the damage. The purpose of this section is to describe proper post-flood treatment.

Things to keep in mind:

  • In case of flood, do not open cabinets and units. It is better to wait until the flood water recedes.
  • If it is possible to drain actively, the early drainage can reduce the damage.

Outline of the procedure after flood water recedes is as follows:

  1. Remove batteries & cables
  2. Wash the units
  3. Dry the units
  4. Check the insulation resistance
  5. Check the functionality (Performed by MRO Electric’s engineers)

Remove batteries & cables

In order to minimize a damage to unit, please perform following at first:

  1. Please remove battery cables from units and PCBs (Printed Circuit Board) as soon as possible. Flooded batteries may cause rust damage to PCB’s circuitry and could result in irreparable PCB damage. Removing the batteries will result in loss of CNC data, but it is necessary to protect the hardware from further damage.
  2. Remove cables before washing. Please properly tag or mark so you will be able to connect cables back correctly.

Washing the Units

Wash the units according to the procedure below as soon as possible. Damage will worsen if washing is delayed.

  1. Unit –  Floodwater often contains contaminates such as dirt and oil. This could stick to the unit and could become difficult to remove. Use a neutral detergent, such as multipurpose kitchen detergent, tap water, and nylon brush (do not use a metal brush) to clean them as much as possible. Use a small brush such as a toothbrush and clean the entire unit with specific attention to connectors and sockets.
  2. Relays –  If relays have water inside, please open the case and clean inside. (If the case cannot be opened, you will need to replace it.)
  3. Transformers –  It is not possible to clean inside a transformer coil, however, please clean the unit as much as possible especially around the electrical terminals.
  4. Cables –  Connector housings will contain flood water. Please disassemble the connectors to drain any water, clean them, and then dry by hanging the cable with the connector at the bottom. (It is also possible that flood water also enters between cable strands). Please be mindful of this.
  5. Servo and Spindle Motors – These motors cannot be disassembled by the customer.
    Please have MRO Electric’s engineers clean these parts. If you see waters entering inside the cover on the motor, the cover may be removed to release the water and carefully clean around the feedback assembly.
  6. Motor Drive Units – Please use flowing water to clean the motor drive units. Please refrain from submerging the unit during cleaning.

Drying Units

After washing, please remove as much water as possible and let then dry. The electrical resistance is lower due to the moisture, so please do not attempt to mount or apply electrical power until the unit is completely dry. It will take a long time if you just leave the unit at room temperature. Transformers, especially, will require a few months if not dried to high temperature. It is necessary to use a high heat to evaporate the humidity inside the transformer.

Drying Oven
It is possible to gain enough insulation back in a few hours if you can use a drying oven with enough high heat. However, please be careful if the temperature is too high, it may melt the insulation material. A vacuum type drying oven may be useful for this type of equipment.

Here are a few examples of temperature and drying time for FANUC products, after removing as much water as possible by hand:
· Servo Transformer – In 120 degree C (248 degrees F) for 8 hours
· Servo Motors – In 80 degree C (176 degrees F) for 12 hours (with Pulse coder removed)
· PCB (Printed Circuit Boards) – In 60 degree C (140 degrees F) for 1 hour.

Without a Drying Oven
Please prepare a fanned heater. It is a good idea to use a hair dryer to send heated air (around 140 degrees F is desirable). Please be careful as it may become too hot if you send the air directly to the unit. PCB and units may be dried in a half, to one full day, but the transformer may take a few days.

Check the Insulation Resistance

It is very important that insulation resistance is tested before applying power.

  1. Transformer – Measure the insulation resistance using 500V Megameter between coils, and between coil and metals such as core. The measurement should be 10 Megohm or more.
  2. Servo Motors and Spindle Motors – Measure the insulation resistance between the motor windings and ground. The measurement should be 10 Megohm or more. Please note that the encoders may be damaged by the flood water. Please open the motor case and check. If you see the sign of entering the water, the encoders may need to be replaced.

Check the Functionality

MRO Electric engineers and machine tool builder engineers may need to work in sync because machine side repair and adjustment will also be required. If the insulation resistance is adequate, then the unit may be installed. Confirm all cable connections and wiring, then apply power and confirm the operation. If insulation is not sufficiently recovered due to insufficient drying, there is a possibility of ignition due to short circuit or heat generation, so pay attention to the generation of smell and smoke for a while after energization, immediately turn off the power when there is an abnormality.

If parameters were lost and a recent back up is not readily available, it is our recommendation to contact the machine tool builder to assist you. They will also be able to assist in any machine side adjustments and/or set up procedures before the final operation is started.

Our goal is to quickly and safely return your machine back into production. Do not hesitate to contact MRO Electric if you believe your equipment is damaged and is in need of testing and/or repair, or if you require a replacement part.

Please contact us at 800-691-8511 or at sales@mroelectric.com.

Control Techniques Lineup

Benefits of Buying Refurbished Industrial Automation Equipment

Joe Kaminski Leave a comment

At MRO Electric and Supply, we offer a wide range of repaired, refurbished and reconditioned automation products for each of our manufacturer lines. We never supply used, untested, second-hand parts. Each of our refurbished parts is fully cleaned, serviced, functionally tested, and upgraded to optimal working order before being made available for sale. We also place each of our reconditioned products in like-new packaging for easy identification, transportation, and storage.

Benefits of Refurbished Automation Products:

1. Availability
For many obsolete and legacy automation product lines, finding new, unused parts can be a challenging task. Oftentimes, searching for unavailable new parts can cause unreasonably long lead times which increases the risk of downtime. MRO Electric stocks a variety of refurbished products with same-day and next-day shipping options, while keeps the risk of downtime to a minimum.

2. Price
Refurbished products tend to be significantly less expensive than new parts. MRO Electric offers many refurbished items for up to 75% less than their new counterparts. This deep discounting allows our customers to stock up on spares while minimizing their costs.

3. Equivalence
Purchasing an exact replacement prevents compatibility issues versus upgrading to a newer component. For some manufacturers, it is better to stick with tried and true systems than risk purchasing a different part that may not function correctly with their process.

4. Reliability
Just because a part has been refurbished does not mean that it won’t last as long as new. Additionally, many of our refurbished parts have seen little or no use throughout their lifetime. We are extremely confident in the reliability of our refurbishment process, and warranty all of our products for a minimum of 12 months.

                            Our Top Manufacturers
 Siemens     FANUC                              Yaskawa          ABB
Control Techniques

Yaskawa Motoman Swordfighter

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Yaskawa Motoman Swordfighter

Industrial robotics is pretty under-recognized It’s easy to think they’re all about manufacturing. But just watch as Motoman-MH24 normally found assembling or packing products in a factory, takes on a new lease on its automation life and becomes a master sword fighter.

Motoman-MH24 is a 630-pound high-speed industrial robot made by Japan’s Yaskawa Electric Corporation. The Yaskawa Bushido Project is a short video clip showing Japanese master swordsman and five times Guinness World Record holder Isao Machii teach Motoman-MH24 the way of the sword. The company made this promotional clip to celebrate what they dub “manufacturing spirit” as they near their 100th anniversary.

To date, Machii has demonstrated some pretty radical feats with his blade: slicing a flying shrimp pelleted at him at 80mph in half, and a neon ball flung at him at 150mph – and these are just some of the things the dude can do.

The Yaskawa researchers examined Machii’s sword techniques in 3D. Next, they got Motoman to reproduce the very same movements, and the results are superb. In a showdown between master and robot-apprentice, the pair first demonstrates a four-directional cut in flawless sync. Then Motoman-MH24 reproduces each of Machii’s cuts down to a tee.

Things start really heating up when the robot actually looks like it’s gaining an upper hand over its human trainer. While Machii horizontally slices one orange, Motoman-MH24 takes down six in one fell swoop. The most epic scene is probably the one where Motoman splices a really thin pea pod in half.

While Machii looks visibly tired towards the end of the final “1000 cuts” scene, his mechanical counterpart could probably go on for at least an extra 100000.

Click to view our Yaskawa Drives and Controls currently for sale.