How Can I Add Machine Automation To My Induction Heating Systems And Be More Competitive?
Machine automation gets a bad rap as being too expensive, with a long return-on-investment (ROI). Can machine automation be done more competitively, with a faster ROI, and less work force disruption? Below, I introduce a 3-part answer to that question.
Machine Automation does not have to be expensive!
Cost Effective Machine Automation
In many cases, machine automation can be added to your existing production systems. No need for capital expenditure on new induction machines! A semi or fully-automated system can make your employees more efficient. For instance, with the aid of automation, an operator can run multiple lines at the same time; they could begin an Automation Cycle on line 1 and then continue working on line 2. Automation can help you run more efficiently and save existing jobs while minimizing the cost of having to hire and train temps during peak production times.
Some Real-Life Examples of Cost-Effective Machine Automation Systems:
Soldering System with Automatic Solder Wire Spooling, Applying Soldering – In an Open Air or Vacuum – Argon Atmosphere:
- Inductively heat a workpiece to its target temperature, then apply a pre-determined amount of solder accurately, each and every time. As shown below, an operator can set up the process, press the Start-Cycle button, and then walk away and the system will automatically complete the heat-and-solder cycles.
- Automated wire brazing or using pre-forms.
- Automated annealing stations.
- Forging, vertical and horizontal type, feeding a billet to and from the induction heating coil.
Obsolesce & Future Expansion Concerns
We design our automation systems so that they can always be taken to the next level; a semi-automatic can be converted to a fully automatic, depending on the application and its feasibility, of course.
For Success: Monitor, Document, Repeat
Infra-Red Temperature Measurements & Data Logging: Highly accurate Infra-Red Pyrometers can be added to measure and monitor the workpiece temperatures. All relevant production data and “recipes” can then be uploaded to most third-party database systems (e.g. Industrial Automation 2.0 systems) for analysis and storage.
Increase Production Throughput with Induction Power Supplies Featuring Dual-Output
Advances in Induction Heating allow us to offer a wider variety of heating options than were previously available. We are especially proud to offer our Dual Remote Head Heating Station – heat two workpieces at the same time, even if each workpiece requires different output power, temperature, and time! This new technology can potentially double your production throughput!
One Induction Heating Power Supply With Multiple Outputs. Each Output Can Be Individually Controlled For Power, Temperature & Time
Production Line Back-Up & Redundancy
With the Dual-Output Induction Heating System, you can have two production lines running at the same time, or use the system to improve your up-time by building in redundancy. If the first production line goes down, you can easily switch to the second output and quickly resume production.
Advanced Control & Interface Functions:
Temperature Control, Thermal Profile , Data Logging
The Best Part of Serving Our Customers with Cost Effective Machine Automation:
We love to learn about and help build new applications! We conceptualize, design, prototype, and manufacture all our automation systems in-house at our local West Coast Customer Technical Center. You can evaluate, qualify, and run the automation system prior to the delivery! In most instances, we will also come on-site to install and start-up your system.