A Beginner's Guide to Assembly Line Automation - Inbolt

Before assembly lines, production was done by skilled manual labor and small-scale workshops. Assembly lines marked a significant shift to mass production and standardization, revolutionizing the production process by adding parts to a product in a sequential manner, with each workstation performing a specific task.

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The concept of the assembly line was transformed again by Henry Ford in the early 20th century. His introduction of the moving assembly line drastically cut the time needed to assemble a Model T, reducing it from over 12 hours to just about 90 minutes. This innovation not only made cars more affordable but also set a new standard for mass production across various industries.

Assembly line automation has evolved since Ford's time, ranging from simple, repetitive tasks to complex, multi-step processes, transforming manually operated tasks into sophisticated automated operations.

Let’s take a walk.

What’s “Assembly Line Automation”?

Assembly line automation involves using technology and machines to perform tasks that were traditionally done by humans. The goal is to boost all aspects of the line to produce goods faster, more accurately and at a lower cost, while maintaining high standards.

The Basic Components of an Assembly Line

• Conveyor belts are the highways, responsible for moving parts and products from one workstation to another. Modern conveyors can usually adjust speed, detect issues, and make sure everything gets where it needs to go on time.
• Workstations are the workshops within the assembly line. Each one is set up to handle a specific task (putting together parts, checking quality, etc).
• Robots are the pillars, taking over the repetitive and precise tasks like picking and placing parts, welding, painting, etc.
• Control systems are the brains behind the operation, coordinating everything—conveyor belts, workstations, robots—to make sure everything runs smoothly. These systems monitor the entire process while collecting data that can help improve production strategies.
• Quality Control mechanisms are there to make sure products meet high standards, using automated inspection systems with cameras and sensors (or, in certain cases, humans) to spot defects and ensure everything meets the mark.

But even with all this automation, human-machine collaboration is about combining the strengths of both to boost productivity and keep the production process flexible and innovative.

The Types of Automation Systems

Automation in manufacturing comes in various flavors, each suited to different needs and production styles. Let's take a look:

• Robotic Automation: Robotic automation is exactly what it sounds like—using robots to handle tasks that are often repetitive and require precision. Think about robots welding car frames, painting vehicles, or moving materials around a factory.
• Fixed Automation: Fixed automation, also known as hard automation, is great for the high-volume production of a single product. It involves using specialized equipment to perform specific tasks. While it's cost-effective and efficient for producing large quantities, it lacks flexibility. Once it's set up for a particular product, it’s not easy to change. This makes it ideal for industries like automotive manufacturing, where the same item is produced over and over.
• Programmable Automation: Programmable automation is perfect for batch production, where you can reprogram and reconfigure equipment to handle different tasks and products. It's more flexible than fixed automation but still needs some setup time between different batches, making it suitable for industries where production needs to switch between different products, like electronics manufacturing.
• Flexible Automation: Flexible automation, or soft automation, is incredibly adaptable, allowing for quick changes and easy adaptation to different tasks and products. It’s ideal for environments where product designs change frequently, or custom products are made. Flexible automation systems can switch from one task to another with minimal downtime, making them perfect for industries that need to be agile and responsive to market demands.

The Integration of Advanced Technologies

Advanced technologies have become game-changers in recent years, with four notable integrations:

• Vision Systems

Vision systems use cameras and image processing algorithms to perform tasks like quality inspection and object recognition such as robot guidance, helping them to accurately pick and place components, and to ensure that everything is correctly aligned.

• Artificial Intelligence (AI) and Machine Learning

AI and machine learning can analyze vast amounts of data to predict when equipment will need maintenance, ensuring that machines are serviced before they break down. They can enhance quality control and, in some cases, help in process optimization by making real-time decisions.

inbolt’s 3D vision and AI-powered solution makes industrial robots smarter, making it possible for robots to quickly understand and react to their surroundings, facilitating automation on moving assembly lines.

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• Internet of Things (IoT)

IoT devices enable machines to communicate with each other, sharing data and coordinating actions. For instance, if a machine detects an issue, it can alert other machines and the central control system to adjust operations; it can monitor and manage inventory, and so on.

Siemens’ Amberg Electronics Plant uses IoT sensors throughout its production line to create a fully digitalized factory, enhancing productivity and flexibility.

• Collaborative Robots (Cobots)

Unlike traditional industrial robots that operate in isolation, cobots work alongside human workers. These robots can take over repetitive and strenuous tasks, and are equipped with advanced sensors and safety features to ensure they can interact with humans safely. Here, both robots and humans contribute to the production process.

• Augmented Reality (AR)

AR technology overlays digital information onto the physical environment, providing real-time assistance to workers. In manufacturing, AR can be used for training new employees, guiding them through assembly tasks, and troubleshooting issues (like using AR glasses to see step-by-step instructions or visualize the internal components of a machine they are working on).

Boeing tried to use AR glasses for wiring and maintenance tasks, allowing workers to see real-time instructions and diagnostics overlaid on their field of view.

Future Prospects of Assembly Line Automation

The evolution of technology will continue to redefine assembly line automation. The convergence of all these new technologies and advancements are bound to create smarter, more efficient and adaptable manufacturing processes over time, allowing industries to remain competitive in a dynamic market.

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Many products benefit from a protective finish. There are two ways to apply this coating  — either manually or automatically. Manual application can lead to inconsistent or thick coatings. Instead, many businesses are streamlining their processes by using automated spray coating machines. Automatic spray coating machines are faster and more accurate, saving you time and money. 

What Is Spray Coating?

The manual or automatic process of applying a coating — either a protective finish or paint — to finished products is spray coating. Spray coatings can be a powder, liquid or solidifying agent. It’s a common surface finishing technique because many products made of materials like wood, metal and plastic across a vast number of industries benefit from spray coatings. 

What Is An Automated Spray Coating Machine?

Automated spray coating systems utilize robotic technology to spray a mist of coating onto your products, workpieces or substrates. Their position is fixed in the production line, so they are common at factories and other production sites. Many companies prefer automated spray systems because they only use the necessary amount of coating and apply it evenly.

Why Use Automated Spray Coating Machines?

An efficient way to increase output while maintaining quality is by incorporating new technology into your processes. The benefits of automated spray coating systems include:

• Improved productivity: Automated spray coating machines can perform the same tasks as manual ones quicker. They require less human intervention and monitoring, can spray various liquids and are programmable for different coating types.
• Reduced waste: Automatic spray coating reduces waste in a variety of ways. Because they make fewer errors, they use less finishing products to produce a uniform layer.
• Higher-quality coating: These machines adjust the spray and nozzle height and fluid volume as they coat, ensuring a higher-quality coating that’s clean and consistent.
• Simple operation: Automated spray systems are easy to use and usually only require minimal training.

Types of Automated Spray Coating Systems

There are many types of automated spray coating systems perfect for different applications. The main automated spray machines are:

• Fan coaters: These compact sprayers coat moulding, siding and trim.
• Reciprocating spray machines: Reciprocating spray machines apply finishes to drawer fronts, raised panel doors and flat panels.
• Rotary spray machines: Rotary spray machines can coat interior and exterior doors, 3D and contoured substrates, cabinet doors and flat panels.
• Linear spray machines: Linear spray machines coat moulding, door jambs, wood flooring, siding and cabinet components.

Fan Coaters

These coaters are powerful compact units excellent for UV and water-based moulding, trim and siding coatings. Fan spray coating uses a fan-shaped nozzle to apply a mist of coating to your product’s surface. The Dubois fan coater has many features, including:

• Three easily adjustable fan tips
• A top curtain coating head 
• Dual filters, so you can clean one while the other is in use
• Easy installation and removal of splash guards
• Ability to handle substrates up to 12 inches wide at 100-800 FPM

Reciprocating Spray Machines

Reciprocating spray coating machines use oscillating spray guns, hence the name, to coat a variety of products. The machines apply the product in overlapping waves for a high-quality finish. Dubois has two types of reciprocator spray machines — LD and MD. Both are great for applying finishes to flat panels, drawer fronts and raised panel doors. The primary difference between the LD and MD reciprocating spray machines is that the LD has one oscillating arm, while the MD has spray guns on two independent circuits. 

LD-Reciprocator Spray Machines

The Dubois LD-Reciprocator is suitable for small-and medium-sized enterprises. It offers many features, including:

• Four spray guns
• Color change capabilities
• An exhaust extraction fan
• Dual-stage dry filtration
• Pneumatic Logic Control (PLC) for easy, precise adjustments
• Quick change gun mount
• Spray widths up to 52 inches
• Line speed up to 10 FPM
• Overhead intake air blower
• Self-winding paper conveyor belt for less cleaning

MD-Reciprocator Spray Machines

The Dubois MD-Reciprocator provides a clean finish with its precise spray patterns. Its other benefits include:

• Switching between spray guns for different finishes
• Ability to clean and prepare the other spray gun while one is operating
• Color change capabilities
• PLC control
• Automatic part detection
• Filtered air makeup
• Efficient cleaning
• Rapid finishing material changes
• Exhaust extraction fan
• Dual stage filtration

For optional features, you can select a paper belt or belt cleaning system and choose equipment that’s compatible with medium pressure or HVLP guns. 

Rotary Spray Machines

The spray guns on rotary spray coating machines move in patterns to create a consistent coating. These machines have a head that rotates as pieces move underneath it, which creates a fine, even mist perfect for interior and exterior doors, cabinet doors, flat panels and 3D or contoured substrates. As the parts pass under a scanner, the machine automatically defines their shape and size, then varies the line speed and rotation rate to enhance the coating’s quality. The features of rotary spray machines include the following:

• Four to eight rotating arms
• Programmable spray guns
• Line speeds greater than 30 FPM
• Color change capabilities
• Coating recovery system
• Exhaust filter system

This machine’s optional features include medium pressure or HVLP gun compatibility and a paper belt or belt cleaning system.

Linear Spray Machines 

Linear spray coating machines prime, seal and finish linear stock. As the substrates go through the machine via a conveyor belt, an overhead spray gun coats them. These machines reduce downtime and increase productivity. They’re excellent for coating moulding, door jambs, wood flooring, siding and cabinet components. Dubois has the SP-12 and SR-12 Linear Spray Machines.

SP-12 Linear Spray Machines

The SP-12 has many benefits, such as being easy to clean, and its features include: 

• Water-and solvent-based coatings compatibility
• Three adjustable gun arms
• Infeed guide fences
• Ability to individually enable and disable the guns
• Adjustable fluid pressure
• Automatic on-and-off for guns
• 9 foot long conveyor 
• Adjustable air pressure
• Top roller hold-down

SR-12 Linear Spray Machine

 The SR-12 industrial spray machine features: 

• 24/7 operation
• One or two pump circuits
• Six gun arms
• Hold down roll
• Infeed guide fences
• Gun atomization regulator
• Pump pressure regulator
• 200 feet per minute maximum line speed
• Manual gun triggers
• Filter system
• Compatibility with conveyors, material handling and curing equipment
• High-efficiency overspray arrestors

Explore Premium Surface Coating Machines at Dubois Equipment

The automated spray coating machines at Dubois Equipment can give you the edge you need. They will help you achieve a sleek, even coating and increase your efficiency and output, setting you apart from your competitors. We have been the primary producer of flat-line finishing systems for more than 25 years. Our advanced equipment helps businesses meet their product demand by increasing efficiency and productivity. 

Contact us to discuss your requirements of Automatic Spraying Assembly Line(ar,ru,fr). Our experienced sales team can help you identify the options that best suit your needs.