CASE STUDIES

Every project is unique. Our work spans multiple industries as we implement robotics solutions into CPG manufacturing or assist with OEM manufacturing processes.

PALLETIzING:  Large Paper Cup Converter

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In this application, a robotic system was needed for accurate palletizing of heavy, die-cut paper components to improve plant safety and efficiency.  The mandate for the robot was first to lift multiple, loose die-cut parts from 4 different locations located on die-cutter output lanes.  Second, it needed to palletize each heavy segment, without spillage, into a moving tote exchange system.

 

aXatronics designed, built, project managed and implemented the solution including:

 

1)  Creating a cost-effective, knowledgeable build team partnering

     with with an expert conveyor systems partner to build the

     conveyor portion required for tote handing

2)  Engineered the unique multi-tasking end effector

3)  Programmed the complex path and motion of the robot

Yaskawa Motoman's North American Award

for "Innovation" in robotics in 2015.

AUTOMATED BOW-TYING:

Esther Price Fine Chocolates

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This famous local candy maker needed an automated bow-tying system for its one-pound boxes of chocolates to alleviate worker’s repetitive fatigue injuries.

 

aXatronics designed a box handling system and a remarkable robotic tying solution for handing the ribbon and transforming them into the brand recognized bows that adorn each Esther Price box.  The robot that “ties bows” now allows completion of the boxing process by machine.

DIGITAL SCANNER PROBE:

 For a national non-destructive testing and measurement lab

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This testing laboratory used a servo-motor and cogged belt drive to accurately rotate an Eddy Current sensor.  The cogged belt introduced too much mechanical and electrical noise into the resulting measurement data.  We proposed a design to build a system using an open frame motor to make the rotating shaft part of the motor itself.  This eliminated the belt drive system and the noise.

 

This design was implemented and it worked precisely as designed allowing intricate and precise measurements to be achieved without the noise interference.

 

In addition, the company’s original collet design used a pneumatic rotating collet to hold the measurement probe in the rotating shaft.  This caused issues of seal drag on the shaft as well as air leakage.  We designed a new spring-loaded collet as part of the scanner that had no contact when spinning and the spring retention force was only released when the shaft was not turning.  The mechanical spring collet also holds the probe with greater repeatability and accuracy.

 

Furthermore, it was essential that a new key precision part be readily available due to the constraints of low quantity hardware devices.  Our ability to source unusual components complemented our ability to design innovative hardware in this example.

 

 

MULTI-PICK & PLACE WORK CELL:

For a small manufacturing company

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This small manufacturing company needed a cost effective process to simultaneously feed 12 different tags into exact positions for a die located on a rotary RF welding machine table.  At stake was a job to produce millions of tags for a Fortune 500 company.  We designed a small robotic system with a unique vacuum end effector to store the parts, then pick and place a dozen individual tags onto the targeted tray.  This made the entire process possible and allowed the company to fulfill orders for years.

This adaptable precision pick-and-place technology, called “Cobra Placement Systems” is used by a variety of manufacturing clients from automotive to computer components.  It is scalable and places engineered die-cut components accurately, repeatability within +/- .002” onto a target part.  Placed parts can have adhesive on both sides.  Moreover, they are placed without distortion, allowing components like extremely thin walled gaskets to be placed accurately. Although this technology is a stand-alone work cell, it can be easily integrated into an automated line.

 

Placed components can be made of many materials including but not limited to: transparent materials with adhesive on both side, thin walled gaskets (as thin as .0625”), foams, and even thermally conductive materials. The technology is scalable.

 

Notable features:

 •  Loads new rolls of converted components in

           less than a minute decreasing downtime

 •  Places components of nearly any shape

 •  Places parts every 5 seconds or less depending

          upon application

 •  Easily customized for unique applications

 •  Uses “off the shelf” components

 •  Can position parts as small as .25” square

 •  Optional printer for data or barcoding

 

ADAPTABLE PICK & PLACE WORK CELL:

 Used in a variety of industries / applications - Orders continuing

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MICRO-FRACTURE

DETECTION SYSTEM:

For a national non-destructive testing

and measurement lab

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This national company required a new and portable system to accurately detect microfractures on aluminum seams.  It needed to work on any seam when placed on site on the equipment.  This was driven by safety concerns as equipment was aging.  The portable system was required to accurately hold the sensor perpendicular to the equipment seam during inspection. aXatronics designed and manufactured the electronics’ housings and the method to hold the system in place.  It met every expectation held by the client.

TIER SHEET AUTOMATED PLACEMENT

 For one of the world's largest CPG companies

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The challenge on this project was to create an automated process enabling the placement of  tier sheets or separator sheets between layers of products as they were being palletized.  The tier sheets can be placed as high as 8 feet from floor level.

 

Once the sheet was placed, the entire mechanism had to retract fully into the machine frame as not to obstruct the palletizer.

 

The automated system we designed reliably and accurately placed the tear sheet at whatever height was required on top of the products, keeping pace with the palletizer.

PALLETIZING AUTOMATION

for LARGE CPG COMPANY in 2015

ENGINEERED CUSTOM HARDWARE

TO RESOLVE PRODUCTION ISSUES

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Our ability to design and manufacture unique, key hardware components for challenging applications (shown below) is an asset to our clients. Sometimes it’s the design of a component for a process that makes all the different in repeatability, consistent part production and the desired results.

 

  •  AXATRONICS 2018

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