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7 Applications for Factory Automation in PCB Manufacturing

by Convergix Marketing | Oct 23, 2024 | Feature Article

Component Installation on Circuit Board.

Factory automation accelerates the production of printed circuit boards (PCBs) for high-end electronics.

Electronics come in all shapes and sizes, but one thing almost all of them share is the use of printed circuit boards (PCBs). Circuit boards are a compact and repeatable way to structure intricate components into a small space, making them integral to modern computing. And with more and more devices coming equipped with computer chips such as the Electric Vehicle industry, production of PCBs is only going to continue to rise.

As technology has advanced, these components have grown both smaller and more sophisticated, therefore necessitating the use of automated systems in their production process. Factory automation in PCB production enables higher production outputs, more complex, advanced components, and more reliability and quality control. Furthermore, automated assemblies are only growing more efficient, as they are aided by simulation technologies that can help plan PCB circuit layouts.

As a process that has fully embraced automation, PCBs provide a useful showcase for the capabilities of factory automation in industries that are seeking solutions to their own needs. Here are seven ways PCB manufacturing applies automation technology to streamline production processes.

1. Loading and positioning of components throughout the process.

Circuit board components aren’t just small; they’re also fragile. Careful handling of each piece is required to make sure nothing breaks or is damaged in the production process. Furthermore, each piece must be carefully set in place so that every component is properly aligned. On larger systems like wire bonding technologies in the EV industry, Eagle will integrate multi-axis servo systems to present the customer parts to the bonding technology using vision systems.

Modern robotic technology offers fine-tuned material handling capabilities that can lift, orient, and place components in just the right position for each production stage.

2. Application of soldering paste.

Before components can be positioned on a circuit board, soldering paste must first be applied to the correct areas of the board. This is done by placing a stencil on the circuit board, and then spraying or rolling soldering paste onto the surface.

Automated application technology can carefully control the volume and direction of soldering applications so those excess materials aren’t wasted.

3. Automated mounting and wiring of components.

The task that requires the most precision is that of laying down wiring and plugging various computing components into place. Many of these components are extremely small, and as each circuit board requires a significant number of components, placing them by hand would be a laborious endeavor.

Fortunately, automation saves the day. Each circuit board can be positioned underneath a machine that is programmed to apply circuitry and other components at a rate of ten or twenty per second, without the risk of human error.

4. Testing of circuit board wiring and functionality.

Given the complexity required in assembly, testing PCBs at the end of the assembly is essential to guarantee product quality. For the first step, PCBs are checked to be sure that there are no improperly placed circuits that might prevent a PCB from properly transmitting energy. The second testing step involves using highly technical software to verify that the PCB is working appropriately. Each of these steps requires advanced testing capabilities, which we incorporate into all our assemblies as needed.

5. Miniaturization of components.

Each time a PCB gets smaller, it enables the development of tinier and tinier components. This miniaturization can only be attained with the aid of factory automation. Today’s most advanced automated systems can apply adhesives and lubricants at microscopic levels, allowing for assemblies of similarly microscopic proportions.

6. Tracing of PCB’s throughout the production process.

Apart from assembling components, factory automation can also be used to keep track of them as they move along the production line. In automated product tracing, a bar code or other tracking device is applied to the component, which is then scanned at each checkpoint. These tracking codes help businesses monitor production speed, look for inefficiencies in the process, and pinpoint any production flaws that may occur.

7. Packaging of PCBs.

Finally, with such a high volume of fragile products, businesses need to be able to package them safely for transport and delivery. Automated packaging can wrap, stack, and palletize completed PCBs so that they aren’t damaged on the way to their final destination.

convergix is ready to serve all your factory automation needs.

As leaders in the factory automation industry, we’ve seen our share of new technologies revolutionizing industries. Our favorite challenges come when we take these technologies and develop automated solutions that are more efficient and reliable than previous solutions. And we are always on the lookout for innovative ways to get the job done, be it Industry 4.0 simulation technology that lets us model our assembly methods or advanced monitoring systems that let us trace components through the production line.

If you have an automated assembly need for your business, we encourage you to contact us today. Tell us about your needs, and we’ll tell you about our solution.

How 3D Printing Is Transforming Customized Medicine

by Convergix Marketing | Oct 17, 2024 | Feature Article

3D printing machine for medical products

The healthcare industry has long been characterized by a one-size-fits-all approach. However, with the advent of 3D printing, a new era of customized medicine production is emerging. This revolutionary technology is transforming the way we diagnose, treat, and care for patients, offering unprecedented levels of customization and precision.

The Power of Personalization

One of the most significant advantages of 3D printing in healthcare is its ability to create highly personalized medical products. Unlike traditional manufacturing methods, which produce identical items in large quantities, 3D printing allows for the creation of unique objects tailored to individual needs. This level of customization is particularly beneficial in fields such as prosthetics, implants, and drug delivery systems.

Prosthetics: A New Era of Mobility

Prosthetics have come a long way, but traditional methods often fall short in providing patients with comfortable, functional, and aesthetically pleasing limbs. 3D printing offers a solution by enabling the creation of custom prosthetics that are not only tailored to a patient’s specific anatomy but also their lifestyle and preferences. By using advanced scanning techniques and 3D modeling software, healthcare providers can design prosthetics that seamlessly integrate with the patient’s body, improving mobility, comfort, and overall quality of life.

Implants: Precision and Durability

Implants, such as hip and knee replacements, play a crucial role in restoring function and improving the lives of countless individuals. Traditional implants often require multiple surgeries and adjustments to achieve a proper fit. 3D printing, however, allows for the creation of custom implants that are designed to match the patient’s exact anatomy, reducing the risk of complications and improving long-term outcomes. By using biocompatible materials and advanced manufacturing techniques, 3D-printed implants can offer superior durability, comfort, and functionality.

Drug Delivery Systems: Tailored Treatment

Drug delivery systems are essential for ensuring that medications are delivered to the right place at the right time. Traditional methods often have limitations in terms of accuracy and efficiency. 3D printing offers the potential to create customized drug delivery systems that can be tailored to a patient’s specific needs. By controlling the release rate, dosage, and target area of medication, 3D-printed drug delivery systems can improve treatment outcomes and reduce side effects.

Beyond Prosthetics and Implants

In addition to prosthetics and implants, 3D printing is being used in a wide range of healthcare applications. For example, it can be used to create anatomical models for surgical planning, patient education, and research. It can also be used to produce custom surgical tools and devices, improving precision and efficiency in the operating room.

The Future of Healthcare

The potential of 3D printing in healthcare is vast. As technology continues to advance, we can expect to see even more innovative applications. For example, researchers are exploring the possibility of using 3D printing to create living tissues and organs, offering hope for patients with organ failure or severe injuries.

Challenges and Opportunities

While 3D printing offers tremendous potential, there are also challenges to overcome. One of the main challenges is the regulatory landscape. Ensuring the safety and efficacy of 3D-printed medical products requires rigorous testing and approval processes. Additionally, the cost of 3D printing can be a barrier to widespread adoption, especially in developing countries.

Despite these challenges, the future of 3D printing in healthcare is bright. By addressing regulatory hurdles and reducing costs, we can unlock the full potential of this technology and improve the lives of millions of people around the world.

4 Ways AGV/AMR Technology Can Revolutionize Your Logistics

by Convergix Marketing | Oct 9, 2024 | Feature Article

In today’s fast-paced manufacturing environment, efficiency and productivity are paramount. Automation and robotic technologies have emerged as powerful tools to address these challenges. Among them, Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) are playing a pivotal role in streamlining internal logistics and material movement processes.

1. Just-in-Time Delivery and Reduced WIP

One of the core principles of lean manufacturing is just-in-time (JIT) delivery. AGVs and AMRs can be programmed to deliver materials and components to assembly lines precisely when needed, minimizing work-in-progress (WIP) and reducing costs associated with inventory storage. By automating material handling, these robots help eliminate bottlenecks and ensure a smooth flow of production. This is especially helpful during peak periods in your business year, such as the holidays for the retail industry.

2. Flexible Assembly Line Design

The flexibility offered by AGVs and AMRs is a game-changer for manufacturing facilities. As production needs evolve, these robots can be easily reprogrammed to adapt to new layouts and processes. Unlike fixed conveyors or static storage systems, AMRs can be moved and redeployed as required, providing greater adaptability and efficiency.

This flexibility extends beyond simple route changes. AMRs can be integrated with other automation systems, such as automated storage and retrieval systems (AS/RS) or robotic arms, to create a fully connected and automated production environment. For example, an AMR could autonomously pick up a part from an AS/RS and deliver it to a robotic arm for further processing.

3. Enhanced Safety and Reduced Human Error

AGVs and AMRs operate on predefined paths and avoid obstacles, significantly reducing the risk of collisions and accidents. This eliminates the potential for human error associated with manual material handling tasks. By automating routine tasks, these robots free up human workers to focus on more complex and value-added activities.

Furthermore, AGVs and AMRs can be equipped with sensors and safety features to prevent accidents and protect workers. For instance, some robots are equipped with LiDAR (Light Detection and Ranging) technology, which allows them to create a 3D map of their surroundings and detect obstacles in real time. Additionally, they can be programmed to slow down or stop when they detect a human or another robot nearby.

4. Improved Efficiency and Cost Savings

By automating material handling tasks, AGVs and AMRs can improve overall efficiency and reduce operational costs. These robots operate 24/7, eliminating downtime and increasing productivity. Additionally, they can help optimize transportation routes and minimize material handling time, resulting in significant cost savings.

One of the key benefits of AGVs and AMRs is their ability to reduce labor costs. By automating repetitive and time-consuming tasks, these robots can free up human workers to focus on more strategic and higher-value activities. This can lead to increased productivity and reduced labor costs.

Moreover, AGVs and AMRs can help to improve the overall quality of products. By reducing the risk of human error and ensuring that materials are delivered to the right place at the right time, these robots can help to prevent defects and improve product quality.

AGVs and AMRs are powerful tools that can revolutionize internal logistics operations. By automating material handling, improving efficiency, and enhancing safety, these technologies can help businesses achieve greater productivity, reduce costs, and stay competitive in today’s demanding market. If you’re looking to streamline your manufacturing processes and improve your bottom line, consider implementing AGV and AMR technology.

9 Ways Advanced Automation Improves Food Safety

by Convergix Marketing | Oct 2, 2024 | Feature Article

Macaroni noodles being processed through automated manufacturing machine

Revamping Food Safety and Efficiency: The Power of Automation

The safety of our food is often taken for granted, both by consumers and by food manufacturers. When we purchase a product at the grocery store, we expect it to be safe for our families. While large-scale foodborne outbreaks are rare, the consequences for companies that experience a food safety failure can be severe, both in terms of brand reputation, legal liability, and financial loss.

Automation offers a powerful solution to these challenges. It can significantly enhance food safety, by preventing contaminants from entering the production process, detecting them when they do occur, and facilitating efficient recalls. Here’s how:

1. Enhanced Supply Chain Visibility

Automation enables accurate tracking of ingredients from source to shelf, making it easier to identify and address potential contamination issues. In addition, automated systems provide real-time visibility into inventory levels, helping to prevent spoilage and ensure timely recalls. Having greater visibility over your supply chain with updated automation systems is the best way to achieve all this.

2. Improved Hygiene with Robotics

Robots can be thoroughly sanitized, minimizing the risk of human-introduced contaminants. Automation can assist, monitor, or replace human workers in many production tasks, reducing the potential for errors and improving overall efficiency. They can provide a safety net for human error to catch mistakes as they are made.

3. Automated Cleaning Procedures

Automated cleaning processes ensure that equipment is consistently sanitized, preventing the spread of pathogens. Automated cleaning reduces the time and effort required for manual cleaning, and can provide more thorough and efficient sanitation. This frees up resources that you can invest in other tasks.

4. Accurate Pathogen Detection

Automated testing systems can detect pathogens early in the production process, allowing for timely intervention and prevention of outbreaks. This not only prevents very costly outbreaks from getting to the shelves in retail stores, but also allows to catch it early enough that you save on waste before it becomes more expensive.

5. Consistent Production for Quality Control

Automation minimizes the risk of human errors that can lead to product defects or contamination. Consistent production processes increase efficiency and reduce waste.

6. Automated Packaging for Freshness and Shelf Stability

Automated packaging systems can handle products quickly and accurately, preserving freshness and extending shelf life. Efficient packaging reduces the risk of product damage and spoilage, minimizing waste.

7. Enhanced Traceability for Targeted Recalls

Automated data collection and analysis enable food manufacturers to identify the source of contamination and implement targeted recalls. Targeted recalls help to reduce the financial and reputational impact of food safety incidents.

8. Increased Worker Safety

Automation can eliminate or reduce exposure to hazardous materials and equipment, improving worker safety. Automated systems can be designed to reduce the physical strain on workers.

9. Faster Time to Market

Automation streamlines production processes, reducing the time it takes for products to reach consumers. Faster time to market ensures that products reach consumers while they are at their peak freshness.

Automation is not only improving food safety but also enhancing efficiency and reducing costs. By adopting automation technologies, food manufacturers can ensure the safety of their products, protect their brand reputation, and gain a competitive advantage in the marketplace.

If you’re interested in exploring how CONVERGIX Automation Solutions can help your business achieve these goals, please don’t hesitate to contact us. Our team of experts is dedicated to providing tailored solutions that meet your specific needs.

5 Opportunities for Automation in Pharmaceutical Manufacturing

by Convergix Marketing | Sep 12, 2024 | Feature Article

Pharmaceutical items like pill trays, capsules, and more.

The pharmaceutical industry is known for having strict regulations and complex processes. That is one of the biggest reasons why many manufacturers are increasingly turning to automation. It allows companies to enhance efficiency, improve quality, and accelerate time-to-market while still adhering to those strict, complex boundaries. By leveraging advanced technologies, pharmaceutical manufacturers can streamline operations, reduce costs, and stay competitive in a rapidly evolving landscape.

The Benefits of Automation in Pharmaceuticals

Like all advancements in technology, widespread adoption of automated systems did not come quickly. However, by now there are enough known success stories and case studies to show that it not only works, it is where the biggest opportunity lies for pharmaceutical manufacturers to grow their business.

Automation offers numerous advantages for pharmaceutical companies, including:

Increased Efficiency: Automation significantly reduces reliance on manual labor, eliminate errors, and improve both productivity and turnaround times.
Enhanced Quality: Automated systems ensure consistency in product quality by minimizing human error and maintaining precise control over manufacturing processes.
Reduced Costs: Automation reduces operational costs by optimizing resource utilization, minimizing waste, and improving overall efficiency.
Improved Compliance: Automated systems help pharmaceutical companies meet stringent regulatory requirements by ensuring adherence to quality standards and documentation protocols.
Accelerated Innovation: Automation frees up company staff to focus on more creative and innovative tasks, such as accelerating the development of new drugs and treatments.

Key Automation Opportunities

If you have a business in manufacturing pharmaceutical goods, equipment and products without any automated systems yet, you may not know where to start. There are several areas within the pharmaceutical industry that offer significant opportunities for automation.

Here are five of the biggest areas for opportunity:

Manufacturing Processes: Automation can be applied to various manufacturing tasks, such as tablet pressing, capsule filling, and vial sealing. Robotic systems can perform these tasks with precision and speed, reducing the risk of contamination and improving overall product quality.
Laboratory Automation: Automation can streamline laboratory workflows, from sample preparation to data analysis. Automated systems can handle repetitive tasks, such as pipetting and plate handling, freeing up scientists to focus on more complex research activities.
Supply Chain Management: Automation can optimize supply chain operations by automating tasks like inventory management, order fulfillment, and shipping. This can improve efficiency, reduce costs, and ensure timely delivery of materials and products.
Quality Control: Automated inspection systems can perform rigorous quality checks on products throughout the manufacturing process, ensuring compliance with regulatory standards and identifying potential defects early on.
Data Analysis: Automation can help pharmaceutical companies analyze vast amounts of data generated from manufacturing processes, clinical trials, and market research. Advanced analytics tools can identify trends, patterns, and insights that can inform decision-making and drive innovation.

Overcoming Challenges and Considerations

While automation offers numerous benefits, it is strongly recommended that you do your research to understand not just the benefits, but also the potential pitfalls you may have to deal with by adopting it blindly. It is essential to address potential challenges and considerations.

Here are some of the common challenges and considerations that pharmaceutical manufacturer should consider:

Initial Investment: Implementing automation systems can require significant upfront investment. However, the long-term benefits, such as increased efficiency and reduced costs, justifies the initial investment.
Integration with Existing Systems: Integrating automation systems with existing IT infrastructure can be complex. Careful planning and coordination are necessary to ensure seamless integration and avoid disruptions.
Employee Training: Implementing automation may require employees to acquire new skills and adapt to new workflows. Providing adequate training and support is crucial to ensure a successful transition.
Regulatory Compliance: Ensuring that automation systems comply with relevant regulations is essential. Companies should consult with regulatory experts to understand the requirements and ensure compliance.

The Future of Automation in Pharmaceuticals

As technology continues to advance, the role of automation in the pharmaceutical industry is expected to grow even more significant. Emerging technologies, such as artificial intelligence, machine learning, and robotics, have the potential to revolutionize the industry by enabling more sophisticated and intelligent automation solutions.

By embracing automation, pharmaceutical companies can position themselves for long-term success, improve efficiency, enhance quality, and accelerate innovation. By understanding the benefits, challenges, and opportunities, companies can make informed decisions about their automation strategies and reap the rewards of this transformative technology.

5 Reasons Why Automation Improves Solar Energy Manufacturing

by Convergix Marketing | Aug 27, 2024 | Feature Article

Orange Industrial Robot Arm Grabs and Moves Solar Panels on Conveyor. Automated Manufacturing Facilit. Production Line at Modern Bright Factory

The solar industry has witnessed a remarkable transformation, largely driven by advancements in automation technology. From silicon ingot formation to wafer slicing and cell assembly, nearly every stage of solar panel manufacturing relies heavily on automation to achieve the precision, efficiency, and scale required for sustainable energy production.

While automation has significantly streamlined the manufacturing process, there were still areas where human intervention was necessary. Tasks involving delicate handling, such as silicon wafer inspection and installation of large solar arrays, were traditionally performed manually. However, recent breakthroughs in robotics and automation have opened up new possibilities for further efficiency gains.

Advanced Robotics for Precision Handling

Modern robots are now equipped with advanced features such as six-axis articulation, pressure-sensitive grips, and artificial vision systems. These can handle fragile silicon wafers with exceptional care. The robotic operators can perform tasks with greater speed and accuracy than humans, reducing the risk of damage and increasing overall production efficiency.

Automated Quality Control with Vision Systems

Ensuring the quality of solar panels is paramount due to the delicate nature of silicon wafers. Traditionally, visual inspections were conducted manually, which is a time-consuming and error-prone process. Advanced vision systems can now automate these inspections, enabling manufacturers to test more frequently, reduce costs, and improve accuracy.

Mobile Robotics for Outdoor Operations

The installation and maintenance of large-scale solar arrays often involve significant manual labor. Mobile robots can now assist in these tasks, from unloading cargo to performing routine maintenance. This not only speeds up the process but it also creates a safer working environment for human crews and allows them to prioritize more valuable tasks.

Industry 4.0 for Smart Solar Fields

Industry 4.0 technologies are transforming solar fields into intelligent systems. By tracking energy efficiency and implementing automated cleaning schedules, companies can optimize the performance of their solar arrays and reduce water consumption. This adds greater value for their potential customers who are interested in solar technology.

Environmental and Economic Benefits

Automated solar manufacturing systems offer numerous benefits, including increased production efficiency, reduced waste, and lower costs. This makes solar energy a more attractive option for consumers who are looking to get more value out of solar energy before they invest in it. It also offers greater sustainability for people who prioritize the environmental impact solar systems can offer above all else.

Investment in R&D

By automating routine tasks, companies can free up resources to invest in research and development. This enables them to explore new technologies and improve the efficiency and sustainability of solar energy systems.

The world is transitioning towards a cleaner energy future. Solar manufacturing automation plays a crucial role in driving innovation, reducing costs, and ensuring a reliable supply of renewable energy. By embracing these technologies, the solar industry can continue to contribute to a more sustainable and prosperous world.

As the solar industry continues to evolve, automation offers a powerful tool for businesses seeking to improve efficiency, reduce costs, and contribute to a sustainable future. If you’re interested in exploring how automation can benefit your solar manufacturing operations, contact CONVERGIX Automation Solutions today. Our experts can provide tailored solutions to meet your specific needs and help you achieve your sustainability goals.

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