WE DESIGN OPTIMAL SOLUTIONS

OPTIMAL PROJECT

An optimal project is a project tailored to the needs of the customer, but it also fits the budget assumed.

The creation of an optimal solution commences already at the stage of preparing the design assumptions. The starting point are the goals that the customer intends to achieve by robotization. At the same time, Wikpol’s engineers analyze the technical conditions of the investment project, among which the most important are:

Process that is to be robotized
Product characteristics
Production requirements (efficiency, effectiveness, the number and frequency of changes in the formats)
Production conditions
- the space available
- troublesome factors, temperature, humidity
Production technology
Logistics of transporting to the manufacturing department
Flow of materials and elements
Automation level assumed by the customer (full/partial automation)
Requirements to be met by the line in 5, 10 years
Processes occurring upstream and downstream the robot's position

The information collected is the basis for the preparation of the line’s initial concept, which is based on the optimal configuration of the equipment. This is both about choosing and designing the machines, and placing them correctly in functional terms.

WE CREATE OPTIMAL SOLUTIONS, WHICH INCLUDE

the Customer's needs

The amount of the budget adopted

Development options

Production conditions at the plant

In the next step, the engineers proceed with optimizing the concept in order to obtain the indicators assumed and save funds.

At this stage, digital models are a necessary tool which help understand and optimize the production processes by simulating different scenarios and approaches, even before deploying in reality.

SIMULATION OF A LINE IN DIGITAL ENVIRONMENT

A line is simulated in a digital environment based on a virtual version of the actual line. This consists in designing and verifying different manufacturing scenarios.

By testing different variants of the processes that take place on the production line, such as:

  • moving the products and auxiliary materials
  • the type and time of particular operations
  • information flow

we may correctly assess which solution is effective from the client’s point of view.

During the simulation, different aspects of the processes may be verified and optimized:

speed
efficiency
effectiveness
possible collisions
safety
costs
quality

The key simulation tools used at Wikpol are:

1. Software for simulating the robots’ operations
This is used to model a robot’s operation and its control in order to configure quickly and easily. It makes it possible to plan the work paths easily with the use of animation (visualizing the ranges and representing operating cycles precisely). As a result, it helps match the best unit with the given application.

The simulations of the robots include the following parameters:

cycle duration
the robot's movement trajectory
commands
collisions detection
the robot's range
the load of the head
the service life of the robot's axis

2. The software for testing the line’s operation
Robot-based secondary packaging and palletizing lines can be modelled at different levels. This is helpful in designing and verifying all the elements which have a real impact on the efficiency and optimal operation of the system, such as:

the concepts of the line
the manufacturing processes
off-line programming
PLC programming

In the case of the control systems, an important aspect of the testing process is verifying whether or not the program operates in accordance with the control algorithm assumed, and is resistant to interruptions. For this purpose, PLC programmers cause emergency situations to know how to react to the events in the future.

A simulation of a line helps verify possible errors and problems, such as delays in the course of manufacturing processes, or breakdowns of machines, before the factual production line is constructed. The knowledge obtained concerning the actual operation of the line is used to optimize its design.

BENEFITS RESULTING FROM SIMULATING THE LINE:

Cost savings

Time saving

Improved product quality

Optimized operation

Besides the technical and economic aspects, the complete picture of the investment project additionally consists of organizational, ergonomic factors, and also factors related to the safety and data exchange.

OPTIMAL PROJECT

IT solutions applied

SAFETY

Ergonomics

Efficiency

Technical solutions applied

OPTIMAL
PROJECT

Reliability

Durability

Efficiency

Efficiently used equipment

Cost effectiveness

This is particularly important in the case of a large scale production, where each second of a standstill or each error in the production could mean tremendous losses.

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