References
Design and commissioning of fully automated production lines
We undertake the construction of completely custom machines and complete production lines from scratch based on the customer’s specific needs. We implement our projects from „A” to „Z” from a single source, so that you do not have to deal with an array of suppliers and the associated administrative burden. We develop our machine designs and propose unique technical solutions through a multi-round consultation process using the experience and technological knowledge available from your existing manual production processes. In this way, we ensure the development of constructions adapted to the appropriate payback plans (ROI) and available resources (Budget), so that our machines are neither over- nor under-designed to perform a specific task. Before your big investment, we also undertake professional project consulting and help you develop your specifications, regardless of which machine manufacturer you want to utilize for the project. At the same time, we are confident that as a result of the joint professional work that has begun, You will choose us for the design and construction of your equipment.
Automatic screen printing line
Complete production line implementation from concept to realization:
- Preceding professional consultation, project counseling
- Design of layout sketches, generating concepts
- Complete Mechanical, Electrical, PLC design, “stage gate reviews” involving the customer for continuous professional coordination.
- Equipment’s production and offline testing
- On-site installation & commissioning
- Comprehensive documentations, -Operating manuals, Parts catalogs, Maintenance guides, CE certification
- Project follow-up, maintenance contracts
Integrated solutions from one source:
- Complex multi-axis servo drives
- Robotic cells (SCARA, 6-axis) with double gripper effectors
- Pneumatic controls per cell
- Integrated complex Vision systems for quality control and positioning. (Line scan cameras, Lumitrax solutions)
- Production line level integrated control concepts (Modular or centralized according to needs), extensive application of field bus systems
- Collection of manufacturing process and product data to a central server, preventive maintenance warnings
Design and construction of individual custom machinery
The efficiency of a production process can be easily improved by the addition of new production equipment’s or machinery. Custom machine design and production tool development includes machines manufactured for almost any unique purpose and task. From the simple screwing stations to measuring machines or to the more complex automated production lines. They all have in common that they make the production or assembly process easier, in addition to increasing efficiency. Our company undertakes the construction of unique custom machines from concept development to commissioning.
Automatic robotized rotary table end-of-line tester (EOL tester)
- Rotary table based in-line measuring machine with its own control and bus-based communication.
- Latest generation control solutions (Mitsubishi, Keyence, Festo)
- Complex camera-based quality control and product positioning
- On-the-fly gripping and positioning of products arriving on a conveyor belt
- High-speed SCARA robots attached to the machine frame on the loading and unloading side, with a completely separated safety circuit and safety PLC. Cycle time: 2 sec / product
- Integrated high-voltage DC and AC measurement
- Integrated FMP layer thickness measuring
- Fully parameterizable HMI for production processes control. Graphs for maximum visualization.
- Full logging, including the upload of files to the network.
- Authentication of user levels, traceability
- Integration into production lines and production processes (Batch, lot management, etc.)
Infrared dryer with rotating unit
- In-line, -passing material flow heated by 6 infrared tubes in a controlled zonal layout
- Cooling circuit with its own fan, with adjustable cooling control
- Non-contact product surface temperature measurement, heating and cooling zone temperature control
- Extraction of evaporating gases
- Stepper motor-driven chain track speed adapts to the incoming material flow
- Product flow rotation & sorting – row in, column out
Automatic cleaning machine
- Integrated Mitsubishi control concept with production line connection
- Automatic pallet dosing for trouble-free operation (1 hour capacity)
- Multi-zone, separated Safety zones to ensure stoppage free reloading during operation
- Stepper motor drives for extensive parameterization (speeds, torques)
- Product cleaning processes during belt transport:
- Air blade
- Rotary brush cleaning on both sides of the product
- Soft roller rubbing
- Lint-free cleaning cloths
- Ionizer to remove charged particles
- Integrated HMI
- Full logging, including the upload of files to the network.
- Authentication of user levels, traceability
- Integration into production lines and production processes (Batch, lot management, etc.)
Automatic screen printing machine
- Latest generation Mitsubishi control solutions from one source (PLC/HMI/Servo/Robot)
- Multi-axis absolute encoder servo drives, direct drives. (5 pcs)
- Complex camera-based quality control and positioning for circuit printing
- Proportional printing force control and paste dispensing
- Automatic screen cleaning
- Laser measurement and self-calibration
- Fully parameterizable HMI for controlling production processes
- Automatic robot service and semi-automatic human service versions
- Cell control, Safety PLC, control of external peripherals (Buffers, server equipment)
- Full logging, including the upload of files to the network.
- Authentication of user levels, traceability
- Integration into production lines and production processes (Batch, lot management, etc.)
- Ethernet I/P based bus communication with peripherals on the line
SCARA robot cell
Within the framework of one of our automation projects we were tasked to design a new robot cell.
The goal of the SCARA robot cell is to carry out a palletizing operation sequence: dispensing workpieces after sensing intelligently their position, performing the “pick and place” task, – while paying attention to energy efficient solutions. We had to solve the final construction by utilizing already existing units. During the design, the flexibility and compactness of the cell was adjusted according to the customer needs, keeping in mind the maximum protection and safety of the operator. The handling is simple and convenient, and thanks to the digitalization solutions work processes can be followed and monitored online.
The design work was completed in the expected quality and on time.
Multifunctional FIFO/LIFO storers with unique transport solutions
- Automatic storage buffering stations to balance production fluctuations and technological processes for maximum machine utilization
- Complex drives and transport systems (Belt, chain, pneumatic and motorized versions)
- With integrated supplementary stations, Weighing unit with precision scales (0.1mg resolution)
- Vibration protection: granite base, isolated rubber pads
- ESD Protection
- Wind protection
- Fine mechanics
- Integrated into a cell-based control
- With variable capacity and automatic width adjustment as required
Development and automation of existing production equipment
Within the framework of our projects, it is possible to modernize and supplement existing production equipment by adding additional functions and stations. The documentation of our customers’ existing equipment is often incomplete, – therefore the implementation may also include the reverse engineering of the existing equipment’s technical solutions. We undertake the mechanical and electrical renovation of your existing production equipment, as well as the adaptation of its software interface to your needs.
Automatic steel linishing station
Our client had several generations of machines for linishing steel products. He asked to supplement one of his existing machines with an extra station, which is functional on its own, while also being able to take control of the previous machine and supplement it. In the framework of the project, the mechanics of the equipment were also completely renewed, and its components were standardized for compatibility with the new generation equipment.
- Project survey, professional consultation.
- Design phase: complete mechanical and electrical design, PLC programming
- Installation, testing and commissioning at the customer’s site
- Provision of comprehensive technical documentation 2D/3D (Digital TWIN)
- Operation manual, maintenance manual, spare parts catalog
- CE declaration
6-axis machine feeding robot cell
Complete robot cell for the feeding of a rotary table measuring machine. The project included the complete renovation of the control system in the related machines (furnace and rotary table measuring machine) and their integration into the new control concept. The PC-based control of the furnace was replaced by a modern PLC-based control with a touch screen display interface for better transparency of the production parameters:
- Project survey, professional consultation
- Design phase: Full Mechanical, Electrical design, PLC programming
- Complete electrical renovation of the existing equipment in the middle of the machine’s life cycle to maintain production stability, as well as create additional expandability tailored to future needs.
- Integration of the machine unit into the production line control system
- Large size 23” + HMI based on the Mitsubishi Soft-GOT solution.
- Camera (machine vision) based pre and post positioning with an accuracy of ±0.1mm
- 6-axis robot feeding
- Provision of comprehensive technical documentation 2D/3D (Digital TWIN)
- Operation manual, maintenance manual, Parts catalog
- CE declaration
Design of compact custom machines and workstations
We undertake the design and construction of unique, small custom machines with the issuance of the relevant documentation and CE declaration. Based on individual customer requirements, cost-effective solutions can be provided for the automation of maintenance or technological sub-processes.
Semi-automatic polyurethane profile cutting machine
The hydropneumatics rubber cutting equipment created in the project was designed to support our client’s maintenance department. In the framework of the project, the following activities were carried out:
- Project survey, professional consultation
- Design phase, using and incorporating the customer’s existing components
- Making an electrical plan
- PLC and HMI programming
- Testing and commissioning
- Provision of comprehensive technical documentation 2D/3D (Digital TWIN)
- CE declaration
Research & development projects
Sometimes the incoming development requests do not apply to complete machines, but to parts, products, and production technologies. We also deal with simulation supported component optimization, product development, optimization for production or the development of production technologies.
Unique corrugator roll geometry
In the manufacturing of paper corrugated board, the corrugated roller pairs give the corrugated layer the final geometry. This part of the process determines the mechanical properties of the product and thus the range of applications.
We have been designing unique roll surface geometry which can produce a product with the specified parameters. Problems to be solved when determining geometry include not only dimensioning tasks (such as determining the required pressing forces, strength calculations, roller sizing, or simulations), but also avoiding paper tearing and maximizing the paper formatting speed during operation.
A further part of the design process can be prototype production and test machine design, then test operation and fine tuning.
Spur gear optimization
In the automotive industry, particularly in competitive conditions, weight reduction of various machine and drive components become a priority.
The lightweight rotating drive elements are advantageous in many ways: not only the carried total weight will be reduced, but also the inertia of the rotated part. Changes in the above parameters also have a positive effect on the consumption and acceleration of the vehicle. In order to guarantee operational reliability with the desired weight reduction, strength calculations, finite element simulation or even topological optimization may be required.
The task has been complicated by the fact that originally, there were some holes in circular pattern around the axis of rotation. It requires adaptation. Through a variety of solution methods and analysis, we strive for simple, cost-effective modifications that meet client’s needs. With the proposed final geometry, the original spur gear weight was reduced by more than one-third.
After machining, the gear wheel has been reinserted to its place and is still operating properly.
Partners
In today’s competitive economic environment, only a few small or medium-sized enterprises are able to provide a comprehensive, all-encompassing service that fully satisfies the needs of their customers. BBM Engineering is at the disposal of its customers with its extensive network of partners. With us, through unification, standardization and cooperation you can find new synergies and develop your business, thus gaining a market advantage.
