NIGHTMARE ROBOTIZED SYSTEM BUILDERS

costruttori di impianti robotizzati da incubo

The 3 typologies to avoid, if you want to safeguard your production

When I started speaking to a client about problems I was able to solve, I always noticed a certain coldness.

I explained  about my machine, how it could perform within a certain machine timing but the client never  noticed the value of my system and depressed, began to shake his head.

He became sad, and seriously continued shaking his head and I never understood the reason why.

Then the client started telling me his bad experiences with other suppliers, how they accosted him and the problems they stirred up.

At that point I started to understand and courteously I presented my solutions.

With determination the entrepreneur answered: “With the robot this operation is impossible!”

Why? I asked. It’s normal for me!

Like that entrepreneur also you convinced yourself that it is impossible and you found an alternative production stategy…

BUT THERE IS A PROBLEM!

You are loosing money, time and your competitors are getting ready, while you remain part of ancient history.

You are like Neanderthal man trying to make fire from stones, while the others already  have flame-throwing devices!

But I understand you, I would be afraid in investing again, too. Very often I speak with quacks promising the moon, but in the end they are all charlatans.   

Only a few are really important and I can make the difference.

The important thing is to seize it…. and if you don’t seize it you stay behind

Now I will explain to you why what you tried previously did not work,

But before we start, let us see exactly where the problems come from.

If you too think that a demurring machine cannot work, because you own a machine from the competition, or you did a test with him. 

THE 3 TYPOLOGIES TO AVOID IF YOU WANT TO SAFEGUARD YOUR PRODUCTION FROM SURE LOSS OF TIME AND MONEY

  • The ingenuous

  • The desperate

  • The all-round expert

THE INGENUOUS

It is the competitor who thinks that somehow everything will work in the end. He relies on the fact that sooner or later he will reach a satisfactory solution or that you will get tired of seeing him at your company and you will settle down.

He offers you a machine made with “carefree mode”.

He does not consider the problems you may have and has not understand the process.

He proposes a machine that is a robot and tool collage, that have been bought anywhere on the market.

If you buy the machine of an “ingenuous person” at some point you will have to accept the mistakes.

BUT THERE IS A PROBLEM!

You will have a machine that does not work well, that gives you much to do and does not guarantee any financial return.

You settle down and in this way, you will loose time and money.

Every second more you use this machine, the costs will mount up!

THE ALL-ROUND EXPERT

It is the competitor who wants to be an expert in everything.

When he comes in, you hear the trumpet sound: The robotic Emperor!

Your reference point to automate the company.

He offers the warehouse worker robot, automation for the works centre, the industrial robotic painter….

He is the one who wants the humanoid robot (but fortunately does not yet have the funds to start the project.

Normally, the all-round expert has no familiarity with the process, so in the same workstation (there is no better term to define it) he puts everything ….. and contrary to everything: he puts the machine at high speed, and another at low speed, he puts the deburring robot with the piece in its hand and another deburring robot with the tool in its hand. 

Or he installs a robot to take the piece, then leaves it, then takes the tool, then again takes the piece.

I see these machines working and it seems like seeing a drunk walking down the street: he walks miles forward and backwards without reaching his goal.

Or he places a thousand robots for one operation when just one would be enough to perform it correctly.

When you buy a machine from the all-round expert, you think you have struck a deal: he gave you a very complex machine at a price that I personally and honestly would never consider.

BUT THERE IS A PROBLEM!

The complex machine you have, has a secular machine timing and when it stops you need Einstein to find the key to the problem.

He will say it honestly; you did not strike a good deal.

You bought a millstone round your neck which will take you to the bottom of the sea from where nobody will be able to rescue you.

THE DESPERATE

He is the worst of my competitors.

He is worse than the ingenuous person and the all-round expert.

And from my point of view he is worse but above all from YOU!

The desperate is the competitor who has nothing else to do and tries in every way to get the job.

He desperately needs to get the order.

Usually, the desperate has an apparently structured company, a company composed of many people that have to work but above all it has a bank overdraft.

His strength is the commercial network.

In fact, he sends you his vendors to pull wool over your eyes, convincing you that everything that glitters is Gold.

BUT THERE IS A PROBLEM!

With him you invest in the wrong way, with him you loose the train, and he brings you to ruin.

The desperate has to close the orders.

He does not care what he sells.

He does not care if he gives you a machine which makes you a profit, he only wants to close the order.

The machine and the technical solution are only a detail.

The important thing is the PRICE!

On the contrary, personally I toss and turn when the discussion turns to the PRICE

Any problem scares me, I never get nervous when something is wrong.

I know where to fix it, but when it comes to the Price, then I loose my temper.

My desperate competitor is always cheaper than me.

He always has the machine ready for delivery or he can build it within a few days.

And do not think that the desperate is just my microscopic competitor (we say “He and the dog”)!

Very often, my competitor is apparently structured, the more desperate he is (imagine how many people’s salary he must pay )!

Think about the paradox: a competitor with an apparently more structured company than mine is cheaper!

HOW IS IT POSSIBLE?

If you start working with an improvised competitor, you think your problem is solved….

BUT THE PROBLEM IS MUCH BIGGER THAN WHAT YOU CAN SEE!

The desperate purchases a machine for you, fooling you into believing that you are saving money, then you discover he gave you a box with a brick inside!

He gives you the bare necessities while trying to earn as much as possible.

I get nervous because the only thing that can compare with my solution and that of the desperate competitor is the price.

The truth is that: my solution is a competitive Formula 1 car able to win the grand prize, instead he gives you Schumacher’s paper-box instead of a Ferrari!

Now that I have introduced you to the source of the problem, let us see them in detail.

There are those who convince you that it is impossible to build a cutting and deburring machine.

But unfortunately for you this is not the case!

Why did you choose a competitor’s machine?

  • Burr too high – reject pieces
  • Scarce reliability of  deburring programme – reject pieces
  • Non accurate piece cutting
  • Robot deurring timing longer than that of the operator
  • Abnormal tool wear
  • Very short life of cutting-wheel
  • Impossible robot operations
  • Too long setup times

BURR TOO HIGH – REJECT PIECES

It happens often that when there is too high burr to remove. The machine of my competitor machine gets into trouble.

The reason is simple: it is the most complex situation.

The tool used for the operation is wrong.

You have banged your head a thousand times.

You said: I have used the best compensating tool, why doesn’t it work?

BUT THERE IS A PROBLEM!

The compensating tool is not always the best choice.

Many times it is the wrong one.

If you have to deburr an aluminium piece with a variable burr, there is no universal solution.

Depending on the tolerance of the piece, on the burr thickness, on the quality you want to achieve, there are different tools to consider.

I have to solve many solutions, none is interchangeable with the other.

To solve this problem I put this system into the field.

  • I analyse the piece.
  • I decide a strategy based on past experience.
  • I do manual tests or use my machine in order to test the tool.
  • I listen to the vibrations while the tool is working, I listen to the noise of the tool, I watch the signs remaining on the tool, I see the result on the piece. 

The same operation that you think you can do with a compensation cutter can be done with:

  • High power non compensating sawing tool (not all the saws are the same, I design my own and I have a trusted supplier of mine who produces them.)
  • The grinding belt (not all belts are the same and not even the wheels are the same)
  • The file (not all files are alike nor do the file builders manufacture the same product)
  • Compact grinding belt
  • Sanding pad

There is no operation that cannot be performed.

If you can do it by hand then there is also a solution to do it automatically, in a better way and with lower machine timing.

SCARCE RELIABILITY OF THE DEBURRING PROGRAMME – REJECT PIECES

For this problem there are different issues that are superimposed:

  • Wrong working tool
  • Unskilled programmer
  • Improvised working unit
  • Unstable machine without any base
  • Wrong robot, too long or not stable enough
  • Unsafe gripper

I would need a thousand pages to face all the problems  mentioned above.

Let’s talk about the unskilled programmer

All robot programmers esteem themselves as God on Earth

Sometimes I see programmes that are wrong and cause unexpected rejects.

You might well know that to saw with a down-mill or with an up-mill  is not the same thing (working in the same direction, the saw will pull the machine or going in the opposite rotation it will push the material. )

But what is with the rest of the tools?

My competitor’s improvised programmer cannot know how to manage a grinding belt or a file or a cutting a blade.

IT’S NOT HIS FAULT, BUT THE PROBLEM IS ALL YOURS!

Sometimes with the same machine and the same tools we can halve the machine timing, just by changing the robot programme.

But on the contrary, if I do a grinding operation, by pushing the belt I must pay attention that this does not tilt.

I slow down the robot…. Which will give a longer machine timing.

BUT THERE IS A PROBLEM!

Sometimes it happens what the unskilled programmer cannot foresee!

The belt tilts, the piece gets damaged …. AND TAC…HERE’S THE REJECT!

You convince yourself that the process cannot be done with the robot.

The truth is that the programmer made the wrong choice.

It has already happened to me and it will happen again.

Just do the right thing and the timing becomes reliable and becomes half as short.

NON ACCURATE PIECE CUTTING

This problem often happens.

The client tells me: the gripper is precise, the robot as well, but I don’t have 2 pieces cut alike!

There are two reasons for this issue:

  • The gripper is precise, but the jaws are built in the wrong way.
  • The robot is precise, but it is the wrong model.

The gripper is a fundamental part of the whole process.

It must take the piece, not deform it and block it tightly. 

Everybody uses SCHUNK although some grippers work while others do not.

The reason is simple: the project of the jaws is a secret that comes from many years of experience.

I cannot tell you how to do it.

It depends on the piece, on the operations to undertake, on the robot size.

Not all robots are the same.

If you use the wrong robot, then it is the end.

There are several robot brands and different types.

The choice of the right robot is the first step towards success.

If you use the wrong robot there is no possibility of solving the issue.

You can just throw it away and buy another one, this time the right one.

If the robot is wrong, during cutting the work-piece it flexes and cuts every piece unpredictably.

Hopelessly ….. There is no solution.

ROBOT DEBURR TIMING LONGER THAN THAT OF THE OPERATOR

The reason may be as follows:

  • the wrong programme (we talked about that before)
  • improvised tools
  • no compensating units
  • the wrong robot

All the issues are reduced to an improvised machine.

If the tools were not designed to be used by a robotised system you cannot expect great results.

The timing comes from the tools you have.

To solve this problem you need a specific works unit and use it as best you can.

This does not mean replicate what your operator does.

ABNORMAL TOOL WEAR

When you use a saw on my machine, the tool lasts 30.000 pieces, while on the one from my competitor it lasts only 3.000 pieces. 

Why? The reasons are always the same.

I have spent many years understanding  how this should be. The reason for the problems.

Today as I have already told you, to understand what to do to improve the timing, while the robot works I close myself inside the machine (please do not tell this to the many safety officers) and I put a hand on the robot.

I listen to it like we do with horses.

While it works it talks to me and it tells me how to improve the tool life, and it tells me what is wrong.

VERY SHORT LIFE OF THE CUTTING-WHEEL

The reasons for this issue are:

  • The power of the cutting motor is too low.
  • Wrong robot
  • Wrong programme

Let us speak about motor power: If you have a cutting unit with a blade mounted directly on the small dimensioned motor and you want to do important cutting, then you have a problem.

To have a well functioning blade, it must have a motor with the correct power and inertia.

You need a suitable set of bearings for the cutting effort.

If you are contented  with it, then YOU HAVE A PROBLEM!

It si fundamental that the cutting unit is build in the correct way.

You pass from having a blade life for a few pieces to one with a life for thousands of pieces.

I have some clients who, when considering only the blade saving, have had investment returns within 2 years.

IMPOSSIBLE ROBOT OPERATIONS

Many times you have had to content yourself with what your supplier gave to you.

A good seller convinced you that the problem was yours, and that a certain operation had to be done by hand.

BUT THERE IS A PROBLEM!

You do not reduce your production costs, you make an investment that will never come back!

To solve this problem I had to invent many work-units which cannot be found on the market.

These work-units allow that the operator avoids touching the piece.

Every operation you do manually, can also be done with my robot.

TOO LONG FOR SETUP TIMING

To make an efficient machine you do not only need a robot but some units around which it operates.

You need electrical equipment to make your life easy.

I often I meet clients using the control panel of the machine like a coat – hanger.

Maybe you think it is brilliant but they put nothing inside the control panel; while my solution has a lot of components.

BUT THERE IS A PROBLEM!

When you retool the machine you need many hours of work.

You have to remember which parameters you have to change in the robot, how to place new tools, the positions you have to change in the robot, and so on…

The operator makes a mistake and it takes more time.

Thousand of issues making you lame.

You convince yourself that the robot is only suitable for a production of big batches.

THE TRUTH IS DIFFERENT!

The electrical equipment in my solution is exactly needed for a quick setup.

The machine remembers everything you have to change.

It reminds  the operator where to install the tools, checks that everything fits well before starting the timing.

DELETE FOREVER THE 3 TYPES OF NIGHTMARE BUILDERS AND YOU WILL PROTECT YOUR PRODUCTION AGAINST SURE LOSS OF TIME AND MONEY

The system consists in:

  • NO IMPROVESED MACHINES

  • NO COMMERCIAL UNITS

  • NO OPERATOR AT THE CENTRE OF MACHINE TIMING

CONTACT ME IMMEDIATELY TO SOLVE YOUR PRODUCTION PROBLEMS WITHOUT GETTING TRICKED BY THE USUAL CONSTRUCTORS

WRITE TO ME NOW:
piercarlo@castingautomation.com

 

Piercarlo Bonomi
The Main Expert in Robotic Cutting and Deburring Machines

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