In the world of manufacturing, precision and efficiency are paramount. At ONExia Inc., we pride ourselves on delivering cutting-edge automation solutions tailored to meet the unique needs of our clients. Our latest innovation—a custom machine designed to automate the milling of a bespoke fastener—showcases our commitment to excellence. Central to this system is the Asyril Asycube 240, a revolutionary component that plays a critical role in the process. Let’s dive deep into the advantages of the Asycube and the custom platen designed by ONExia that makes this system a standout in the industry.
The Customer’s Challenge: Reducing Downtime
Our customer faced a significant challenge with their existing process: the changeover between parts took approximately eight hours. This extended downtime drastically affected their production efficiency and overall output. They needed a solution that could not only handle their unique fasteners but also minimize changeover time to boost productivity.
The Asyril Asycube 240: Precision and Flexibility
The Asyril Asycube 240 is a state-of-the-art flexible feeder that excels in orienting parts for automated processes. Unlike traditional vibratory feeders, the Asycube 240 utilizes 3-axis vibration technology, which offers several significant advantages:
- Versatility: The Asycube 240 can handle parts of various shapes, sizes, and materials, making it ideal for our custom fastener project. This flexibility reduces the need for multiple feeding systems, thereby streamlining the production process.
- Precision: The 3-axis vibration allows for precise control over part movement, ensuring that the fasteners are accurately oriented before being presented to the vision system. This precision minimizes errors and enhances the overall quality of the final product.
- Speed: With the ability to quickly and accurately orient parts, the Asycube 240 significantly reduces cycle times. This increase in efficiency directly translates to higher throughput and improved productivity.
- Compact Design: The Asycube 240’s compact footprint makes it easy to integrate into existing production lines without requiring significant modifications. This design advantage was crucial in the development of our custom milling machine.
Custom Platen Design: Tailored for Unique Fasteners
While the Asycube 240 provides the flexibility and precision needed to handle various parts, the uniqueness of the fasteners in our project required a specialized solution. That’s where ONExia’s expertise in custom design comes into play. Our engineers developed a bespoke platen that works in tandem with the Asycube 240 to ensure optimal orientation and handling of the fasteners.
- Optimized Part Handling: The custom platen is designed to accommodate the specific dimensions and geometry of the fasteners. This tailored approach ensures that each fastener is positioned correctly for the vision system to inspect.
- Enhanced Stability: By creating a platen that securely holds the fasteners, we eliminate the risk of part movement during the orientation process. This stability is critical for maintaining the accuracy required in subsequent milling operations.
- Seamless Integration: The custom platen seamlessly integrates with the Asycube 240, leveraging its 3-axis vibration capabilities while providing additional support and stability for the fasteners. This integration maximizes the efficiency of the entire system.
The Role of Vision and Mechanical Systems
Once the Asycube 240 and the custom platen have oriented the fasteners, the next stage of the process involves the Cognex vision system. This advanced vision technology confirms the position of each fastener, ensuring that only correctly oriented parts proceed to the milling stage. The vision system’s high accuracy reduces the likelihood of errors, further enhancing the quality of the final product.
Following the vision inspection, a mechanical positioner equipped with a pneumatic gripper takes over. This positioner precisely transfers the fasteners to the custom-designed water jet milling station. The water jet milling process ensures clean, precise cuts, tailored to the specifications required by the customer. Finally, the completed parts are ejected into a bin, ready for packaging and shipment.
The Impact: Eliminating Downtime and Boosting Production
The integration of the Asyril Asycube 240 into our custom milling machine has brought remarkable benefits to our customer. By drastically reducing the changeover time from eight hours to almost zero, the new system has eliminated the long downtime that previously hampered production. This improvement has led to a significant increase in overall production and output, allowing the company to meet customer demands more effectively and efficiently.
The Result: Increased Throughput
The integration of the Asyril Asycube 240 into our custom milling machine exemplifies ONExia Inc.’s commitment to innovation and precision in automation. The Asycube 240’s versatility, precision, and speed, combined with our custom platen design, ensure that even the most unique fasteners are handled with care and accuracy. By leveraging advanced vision and mechanical systems, we’ve created a solution that not only meets but exceeds our client’s expectations.
At ONExia Inc., we’re not just building machines; we’re engineering solutions that drive progress and efficiency in manufacturing. The success of this custom fastener milling machine is a testament to our dedication to delivering the best in automation technology. Have an application where custom integration is needed for an Asyril feeder? Contact us today and get started!