Feature Article Archives - Convergix Automation

What Innovations Are Advancing Electric Vehicle Manufacturing?

by Convergix Marketing | Jan 16, 2025 | Feature Article

A translucent vehicle with all the electric systems visible

Advancements in automation and advanced testing systems are helping to fuel the innovations of electric vehicle technology and manufacturing

Few industries are so committed to constant innovation as the automotive industry. Every few years, automotive manufacturers rethink and redesign every aspect of the automobile from the ground up. In an industry where improvements on the margin yield outsized results, OEMs have a lot to gain from investing heavily in machinery that can produce high-caliber results.

For many years now, the area of automotive manufacturing that has led research and public interest has been electric vehicles—and, by association, autonomous driver technology. These technologies often work hand-in-hand, with cutting-edge electronic vehicles incorporation advanced driver-assistance technology systems, and autonomous vehicles operating on hybrid-electric engines for fuel efficiency.

At Convergix, we are committed to delivering automated platforms that can take your electric vehicle manufacturing and battery testing to the next level. Whether you are an OEM or a supplier, we can provide the equipment you need to remain at the forefront of automotive innovation. Here are three ways our technology is leading the way.

#1) Advanced testing for autonomous systems

Autonomous vehicles rely on two powerful technologies: LIDAR, which scans an environment at high speed and with enough detail to create a dynamic, real-time map of surroundings even as the vehicle is moving, and AI systems that interprets this input and responds by sending directions to the automobile.

The safety of any autonomous vehicle is only as good as the sensors powering it. Accordingly, autonomous systems require extensive testing to ensure they are accurately mapping surrounding environments, and that they are responding quickly enough to avoid accidents.

Very few vehicles currently rely on fully autonomous driving. However, more and more vehicles are equipped with assisted driving technology that combines autonomous systems with human control. These assisted technologies include:

Adaptive cruise control
Lane departure warning
Blind spot detection
Collision warning
Pedestrian warning
Traffic sign detection
Parking assistance

At Convergix, we provide advanced testing systems for autonomous and assisted driving systems. These test technologies can be incorporated into your production equipment so that you can test at any point in the assembly process to be sure your components meet the high standards required of autonomous systems.

#2) Testing and assembly for fuel cells and batteries

Electric vehicles draw their energy from one of two sources: batteries or fuel cells. batteries store energy and need to be recharged after a certain amount of use, fuel cells generate energy from a chemical reaction—most commonly between hydrogen and oxygen, with water as the byproduct—and as a result, require refueling to continue operating.

Each of these technologies is currently undergoing extensive research and testing in order to improve them for electric vehicle use. Already, the advances made by these technologies have extended the range of electric vehicles while also reducing the refueling and recharge time. However, there are still major opportunities for improvement, and the EV manufacturers who find the most efficient solution stand to gain significantly in the automobile market.

The technologies we employ during the assembly process for batteries and fuel cells include robotic handling and assembly and the application of thermal adhesives, catalyst coatings, conductive coatings, and other chemical surface treatments.

We also have advanced testing and verification tools that can be used throughout the assembly process to ensure components meet specification standards. In fact, our battery assembly machine on display at the Rockwell Innovation Center in San Jose will be available for customers to view for the next seven years. Stop in and see for yourself!

#3) Factory automation for EV components

While the components for electric generation and storage power an electric vehicle, they aren’t the only parts required to make an electric vehicle run. An electric vehicle’s drive train functions differently all down the line, from the motor, which is comprised of both a rotor and a stator, to the inverter, which translates direct current to alternating current, to the drive unit, which communicates driver input from the accelerator to the inverter, thereby controlling for speed.

Every one of these components requires its own processes for production, assembly, and testing. Our facilities can do all this, with both in-line and end-of-line testing as needed. Our assembly and test capabilities for EV drive trains include:

EV motors and test stands
Drive units
Inverters
Hybrid engines

We thrive off developing advanced solutions for our customers

The battery equipment we build for electric vehicles are also used in home battery packs, marine applications, consumer products such as headphones and hearing aids. Our automated solutions in this space are also used by the Department of Defence. The advanced testing capabilities we use for autonomous vehicle systems can be applied to other autonomous technologies as well. The assembly techniques we use for EV components are part of the toolkit we use in all our automated factory solutions.

Most importantly, we bring a mindset of efficiency and innovation to every project. We are always looking for ways to improve our assembly design, either by reducing the number of steps required for a full assembly, improving the production quality of components, or shrinking the footprint of the production equipment on the factory floor.

We are prepared to apply the same dedication to your project. If you are looking for an automation partner to design systems for your factory, contact us. We can discuss your project, our capabilities, and come to a solution that will yield the results you need.

How Factory Automation Supports the Medical Device Industry

by Convergix Marketing | Jan 2, 2025 | Feature Article

Advanced Medical Printer Producing Artificial Heart Valves with Biopolymers.

Medical devices are subject to strict regulations and high-quality control standards. Automation can help.

The healthcare industry is among the most highly advanced manufacturing fields in the world, with tight controls and restrictions governing the development and production of medical devices at every stage. At the same time, researchers and developers in the healthcare industry benefit from manufacturing solutions that are flexible, reliable, and innovative.

The tension in the healthcare industry between innovation and regulation has historically been difficult to balance. However, factory automation offers a resolution to some of these competing priorities by helping medical device manufacturers produce cutting-edge products that meet even the most stringent industry requirements. Here’s how:

1. Automation offers advanced quality control measures

Quality control is important in every industry, but in healthcare, the consequences of a flawed device can be dire. As such, advanced quality control measures are even more important.

Automation already directly benefits production quality by enhancing standardization and removing opportunities for human error. A human operator on an assembly line will have limits to their consistency. Some inconsistencies may not have significant impacts, but others might be flaws in themselves or lead to flaws further down the production line. Automation is not only more consistent than manual production but can be optimized to a more precise tolerance level than what human workers can achieve.

Given the quality benefits of automation in the manufacturing process, it’s only natural to apply these same processes to testing and inspection. Traditional quality control measures have used mistake-proofing techniques to prevent defects as they occur. Modern methods, such as vision technology and advanced sensors, expand the range of quality testing a company can incorporate directly into the production lines.

2. Advanced robotics help manufacturers keep their operations flexible

Stationary automated assembly lines have long been the standard for many high-volume manufacturers, but the downside of these assemblies is that the specialized equipment cannot easily be switched over to new uses if a production technique changes, or if market demand suddenly shifts. Given the myriad supply chain disruptions, industries around the world have faced since the onset of the Covid-19 pandemic, manufacturing flexibility is a growing priority in some sectors.

Modern robots offer a compelling solution. With a range of effectors that can be rapidly switched during an assembly, a single robot can perform numerous operations repeatedly and consistently. Programming robots has also become more user-friendly, with some interfaces allowing an operator to easily reprogram a robot with the push of a few buttons.

This means that robots are now able to work alongside human operators, assisting in routine tasks both on the factory floor and in other work settings.

3. Manufacturing consistency helps devices meet FDA approval

While flexibility around production can help manufacturers change gears in a pinch, consistency also has its benefits. Medical devices must meet various levels of FDA approval, with entirely novel devices requiring a higher standard and longer approval process than those that are similar to devices already being produced.

If a proven production process is used to produce components of a new device, this similarity works in the manufacturer’s favor. In this way, a consistent production process not only means more reliable quality control but also a faster approval process.

4. High-mix, low-volume (HMLV) production allows for customization

While some medical devices are suited for production by the millions, others are complex enough that a manufacturer may only receive orders in the hundreds or thousands. For these devices, which have a high variety of components, manufacturers benefit from sophisticated automated solutions, such as those that can be provided by the latest high-end robots.

Similarly, some medical devices need to be customized for the patient. These are the kinds of extremely low-volume products that have typically eluded automation.

5. Production tracking helps businesses meet compliance standards

Some medical devices require manufacturers to be able to trace the production process of individual components through each stage of the automated assembly line. This is especially true for a device that might be implanted within a human body, like a pacemaker. If there ends up being a fault with the device, then it is essential that this flaw can be traced back to its point of origin, so that any other faulty devices can be identified.

Factory automation will fuel advances in the medical device technology of the future

Automation has already revolutionized the medical device industry, but Industry 4.0 promises to bring even more change. Advanced simulations will give device manufacturers innovative ways to model their assemblies; IIoT and Big Data will provide new tracking tools and deeper insights into production methods, and augmented reality will transform how operators interact with equipment.

At CONVERGIX Automation Solutions, our expertise in the healthcare industry means we know how to meet class 10,000 cleanroom standards, GAMP regulations, and FDA regulations. Our team can work with your business to provide expert guidance in the development of automated assemblies for medical devices. Contact us today to learn more.

3 Main Sources of Food Contamination

by Convergix Marketing | Dec 26, 2024 | Feature Article

Salmonella in eggs, E. Coli bacteria in ground beef, and pesticides in infant formula are just a few contaminations since the turn of the century that have ravaged the food supply and crippled the food processing and manufacturing industries. Convergix and other equipment manufacturers work hard to ensure that contamination does not originate from the machines designed to process and package food.

We manufacture systems that package and fill food products safely. However, food contaminants may still breach the machinery and infect the food being processed. Below is a list of the most common contamination points that you should address in your manufacturing process.

1) Contamination from the Source

Meat, raw veggies, eggs and milk can be contaminated with E. Coli, salmonella or other foodborne pathogens before they even reach the processing plant. These products are exposed while in or on the ground through contact with animal feces, bacterial infection, and contaminated ground water. According to the Centers for Disease Control and Prevention, eggs are often contaminated before they are deposited by the hen, due to salmonella present in the hen’s ovaries.

2) Contact in Pre-Processing

Slaughterhouses are notorious for co-mingling meats before and after slaughter, leading to contamination. This is because animals typically carry a lot of bacteria and germs in organs like the intestines and skin, which can easily spread to portions of meat during butchering. It is crucial to have a vigilant process to identify contaminated meat.

Contact with pathogens can also occur during transit, especially when the food is sitting idle in the back of a hot truck. Improperly cooled or heated food only heightens the problem. Food that initially contains only a few microbes can become a teeming piece of bacterial heaven after sitting in transit for a few hours.

3) PROBLEMS DURING PROCESSING

Contamination during processing can involve environmental contaminants like metal shavings, pesticides and chemicals used to operate and maintain machinery. Convergix and many other companies incorporate safety measures to ensure food safety during manufacturing. However, contamination can still occur from improper maintenance, improper use of the machines and breaches in the ventilation system that leads to the processing area.

Here are some of the more common examples:

Contaminated water or ice being used during the washing or packing process, especially with fruits and vegetables that are washed before packaging.
Bacteria can easily contaminate the surfaces that are involved during food processing, such as storage bins and processing lines.

Most contaminants can be defeated after processing with high heat or freezing. Other types of contaminants require immediate disposal of the food. Convergix offers a wide array of services in the Consumer industry to help our customers with proper installation, maintenance and operation of all the equipment purchased. We provide solutions to improve food handling safety, including stainless steel parts, sanitation processes, and testing and detecting contamination.

AGVs and AMRs: Your Secret Weapon for Holiday Success

by Convergix Marketing | Dec 12, 2024 | Feature Article

Black Autonomous Robotic Vehicles (AGVs) transporting goods in retail warehouse

The holiday season, marked by events like Black Friday and Christmas, brings a surge in consumer activity. While this surge is a boon for retailers, it also presents a significant challenge. The sudden influx of orders can overwhelm supply chains, leading to delays, stockouts, and dissatisfied customers. Logistics operations, from warehousing to transportation, face immense pressure to keep up with the demand. This increased activity can strain existing resources, leading to operational bottlenecks and increased costs.

With heightened demand, tight deadlines, and the pressure to deliver, optimizing operations and streamlining processes becomes paramount. Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) are emerging as powerful tools to navigate these busy periods.

Understanding AGVs and AMRs

AGVs are industrial vehicles that follow a defined path, often using wires or magnetic tape. They are well-suited for repetitive tasks in structured environments. For example, they can transport pallets of goods from the receiving dock to storage locations or move finished products to the shipping area.

AMRs, on the other hand, are more flexible. They use advanced sensors and artificial intelligence to navigate dynamic environments, adapting to changing conditions and performing a wider range of tasks. They can independently navigate warehouse aisles, avoid obstacles, and adapt to changes in the layout.

Benefits of AGVs and AMRs in Peak Seasons

1) Increased Efficiency

Faster Order Fulfillment: AGVs and AMRs can rapidly transport goods within warehouses, reducing lead times and improving order accuracy. This is crucial during peak seasons when order volumes surge.

Optimized Workflows: By automating repetitive tasks, these robots free up human workers to focus on more complex and strategic activities, such as quality control, problem-solving, and customer service.

Improved Inventory Management: AGVs and AMRs can help maintain accurate inventory levels by efficiently moving goods between storage locations and picking stations. This reduces the risk of stockouts and overstock.

2) Enhanced Safety

Reduced Accidents: Automating material handling minimizes the risk of workplace injuries, such as strains, sprains, and collisions.

Safer Working Conditions: AGVs and AMRs can operate in hazardous environments, protecting human workers from exposure to harmful substances or extreme conditions.

3) Greater Flexibility

Adaptability to Changing Demands: AGVs and AMRs can be easily reprogrammed to handle fluctuations in order volume and product mix. This flexibility is essential during peak seasons when demand can vary significantly.

Scalability: As businesses grow, fleets of AGVs and AMRs can be expanded to meet increased demand without requiring significant infrastructure changes.

4) Cost Reduction

Lower Labor Costs: Automation can reduce the need for manual labor, leading to significant cost savings.

Improved Space Utilization: These robots can help maximize warehouse space by optimizing storage and retrieval processes.

Convergix: Your Partner in Automation

Convergix Automation Solutions is a leading provider of AGV and AMR solutions. Our experts can design and implement a customized automation strategy tailored to your specific needs. From initial consultation to ongoing support, we are committed to helping you achieve operational excellence.

By embracing the power of automation with AGVs and AMRs, businesses can navigate the holiday rush with greater efficiency, safety, and cost-effectiveness. Contact Convergix today to learn more about how these innovative technologies can transform your operations.

Harnessing Automation to Overcome Labor Shortages

by Convergix Marketing | Dec 5, 2024 | Feature Article

Female engineer looking at automation visuals

A Collaborative Effort by Industry Leaders

In a recent article by Jack Uhl of Convergix Automation Solutions and Stacy Kelly of Rockwell Automation, the pressing issue of labor shortages in the manufacturing industry is addressed. The article highlights the potential of automation to mitigate these challenges and drive productivity.

Here are the key takeaways:

1. Optimize Uptime and Productivity:

Implement efficient processes and unify industrial and robot controls.
Utilize smart motion systems and digitalized quality management systems.
Leverage computerized maintenance management systems (CMMS).

2. Accelerate Time to Market with Digital Twins:

Streamline new builds and line changes in a virtual environment.
Analyze machine operations and identify improvement opportunities.
Utilize virtual commissioning to validate and debug machines.
Employ smart objects and integrated design environments.

3. Empower the Workforce with Data:

Utilize visualization and analytics software for real-time insights.
Employ AI and machine learning for predictive and prescriptive analytics.
Leverage augmented reality (AR) tools for guided processes and maintenance.

4. Integrate Smarter Technologies:

Create truly integrated smart machines that optimize all aspects of their life cycle.
Focus on holistic technology integration for enhanced productivity, agility, and resilience.

By embracing automation and leveraging advanced technologies, manufacturers can not only address labor shortages but also unlock new levels of efficiency, innovation, and competitiveness.

To delve deeper into these strategies and learn more about how automation can revolutionize your manufacturing operations, read the full article here.

7 Advantages of Friction and Spin Welding

by Convergix Marketing | Nov 28, 2024 | Feature Article

Friction welding is a versatile and efficient material joining method that offers numerous benefits for manufacturers. By understanding its core principles and advantages, you can harness its power to optimize your production processes.

What is Friction Welding?

Friction welding is a solid-state joining process that utilizes the heat generated by friction to bond two materials. This technique eliminates the need for external heat sources, such as flames or lasers, making it a cleaner and more precise process.

Key Advantages of Friction and Spin Welding

1. Rapid Joining

Friction welding is incredibly fast. Once the rotating component reaches the required speed, the weld forms in a matter of seconds. This efficiency significantly reduces cycle times and boosts overall productivity.

2. Joining Dissimilar Metals

One of the most significant advantages of friction welding is its ability to join dissimilar metals. This opens up a wide range of possibilities for engineers and designers. Some common examples of dissimilar metal joints achievable through friction welding include:

Titanium to copper
Copper to aluminum
Aluminum to steel
Copper to steel
Steel to nickel alloy
Thermoplastics to metals

3. Self-Cleaning Process

The high-speed relative motion between the components during friction welding effectively cleans the surfaces, eliminating the need for extensive pre-cleaning. This reduces preparation time and minimizes the risk of contaminants affecting the weld quality.

4. No Filler Metals Required

Unlike traditional welding methods that rely on filler metals, friction welding creates a strong bond solely through the heat generated by friction and pressure. This eliminates the need for additional materials, simplifying the process and reducing costs.

5. Safe and Eco-Friendly

Friction welding is a safer and more environmentally friendly process compared to traditional welding methods. It eliminates the need for harmful gases, fumes, and cleaning agents, reducing the impact on both workers and the environment.

6. Strong and Lightweight Joints

Friction welds are known for their exceptional strength and durability. By avoiding the weight of additional fasteners or filler metals, friction welding helps to reduce the overall weight of components, making it ideal for applications where weight reduction is critical, such as aerospace and automotive industries.

7. Localized Heat Input

The heat generated during friction welding is highly localized, affecting only a small portion of the material. This minimizes the risk of heat damage to surrounding components and allows for precise control over the welding process.

When to Consider Friction Welding

While friction welding offers numerous advantages, it’s essential to consider its limitations and suitability for specific applications. Friction welding is best suited for joining components with similar cross-sections and sufficient thickness. It may not be ideal for thin-walled components or those with complex geometries.

Convergix: Your Partner in Friction Welding Solutions

At Convergix, we specialize in providing innovative automation solutions, including friction welding systems. Our team of experts can help you determine if friction welding is the right choice for your specific needs and design a customized solution to meet your requirements.

By leveraging the power of friction welding and partnering with Convergix, you can enhance your manufacturing processes, improve product quality, and achieve significant cost savings.

Contact us today to learn more about how Convergix can help you optimize your production with friction welding.

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