Posted by Mark Howe on Tue, Feb 21, 2012 @ 09:42 AM
Here is a brief list with some assembly tips and tricks for 80/20 T-slotted Aluminum extrusion. Please share any tips we missed!
Panel Gasket
- Automotive vinyl protectant applied to rubber panel gasket makes installation easier.
- Cut rubber panel gasket 2-3" longer than the opening to make the corners stay tight
- When installing rubber gasket, start by tucking each end in, then work from the middle out
End Fasteners
- When working with end fasteners, pre-assemble the bolt to snug, then back off a 1/4 turn to easily slide the fastener into the T-slot.
Linear Bearings
- If your linear bearings are not sliding properly, try tapping them with a soft face mallet to align the pads with the T-slot.
Panels
- Leave the protective film on the panels to protect them during installation; just roll up the edges until your project is fully assembled.
Joining Plates
- When using joining plates or gussets, leave the bolts loose and clamp the bars to ensure a square fit before you tighten the bolts completely.
End caps
- Tired of end caps popping off? Tap the end of the extrusion. The threads will prevent the plastic plug from popping out.
Posted by Rick Howe on Mon, Feb 06, 2012 @ 12:22 PM
There are a few things to consider when specifying the correct air cylinder for the right job so you maximize performance and longevity, while giving you lower operating costs for the duration of your application.
Here are a few points to consider in the selection of air cylinders:
- Weight- What is the weight of the load that you need to move? Select a force factor that is 25% greater than the load to help compensate for friction.
- Speed- How fast will you be moving the load? When you have higher speeds you will need to increase your force factor to move the load quicker. Depending on speed and weight the force factor could be as much as twice or greater than the load itself.
- Air Pressure- This is critical for the proper performance and getting the most life out of an air cylinder. Too low of a pressure and your load won’t be moved efficiently or speed requirements not met. Too high of a pressure creates stress on the cylinder and could possibly damage the cylinder as well as the load.
- Bore Size- Select the correct bore size to determine your force factor at your selected pressure. There are charts available to assist in this selection from the manufacturers or you can consult with your Automation Specialist.
- Mounts- How a cylinder gets mounted affects the performance and life expectancy. By selecting the correct cylinder mount you will optimize cylinder strength, efficiency and alignment. Selecting the correct Pivot or Rigid mounting style will help you avoid side load problems which are the major cause of cylinder failure.
Posted by Todd Youngblood on Tue, Jan 31, 2012 @ 09:31 AM
Editor's Note: This is a guest post from Todd Youngblood of The YPS Group.
None of us can afford to waste time. Quite the opposite, we’re all constantly on the lookout for ways to save time. How about some easy pickins’? The process of customer/sales rep communication absolutely screams for streamlining.
Let’s say you’re an engineer looking to acquire “System X” or solve “Problem Y.” You’ll almost certainly start with some Internet research, narrow the field of suppliers, then invite 3-5 sales reps for a face-to-face meeting to get into due diligence.
How different are those 3-5 meetings? The sales folks have all been thoroughly trained in consultative selling. They all ask about your goals, your objectives, your strategy, your challenges, your requirements, what keeps you up at night, your decision process & criteria and what you’re looking for in a supplier. Ughhhh... How sick of answering the same questions over and over do you get?
Did you ever think about how sick the sales crowd is of asking the same questions over and over? Or how about the rest of the meeting ritual?
There’s you walking from your office to the reception area - and then back - with the inane chatter - and a stop at the coffee pot - and settling in seats - and swapping of business cards - and thank yous and you’re welcomes... All before the barrage of repetitive questions. Ughhhh...
It gets worse! The complexity of most decisions these days means you need to involve colleagues, bosses and subordinates; you’ll use a “decision network.” All of the above gets repeated 3-5 times by multiple other people in your organization.
There’s a better way. A few of the more advanced sales organizations are beginning to use a concept known as “e-Rep .” The notion is to embed the knowledge, insight and experience of the sales professional into electronic formats: text, image, audio, video and combinations thereof. That information is then available to you on-demand, at your convenience, 24 X 7 X 365. If it’s good stuff, you can forward it along to others in the decision network.
The concept applies to the buying side of the equation as well. Back to the example of the engineer looking for a solution... Answer all those standard questions about goals, objectives, features, functions, specifications, etc. in a short video, for example. Do it just once! Then send it to your long list of potential suppliers and take it from there.
Figure 15 minutes per meeting gets burned with walking, greeting, business card exchanging, etc. Take 5 sales reps X 5 people in a decision network and over 6 hours goes out the window never to be seen again.
Seems like a no-brainer to me. And that’s only considering the very beginning of the buying process. As a customer, it only makes sense to insist that your suppliers begin using the e-Rep concept right now! And the best way to start is to create your own “e-Buyer.”
Todd Youngblood learns quickly & shares everything he knows. Thirty plus years of methodical, relentless, “Think – Act – Analyze – Repeat” in the sales and marketing wars has generated an outsized mass of field-tested knowledge and insight. His education continues. Learn more at ypsgroup.com
Posted by Mark Howe on Mon, Jan 09, 2012 @ 12:35 AM
You have an application that requires you to move product from point a to point b. The most logical method is to use a conveyor. Before you get overwhelmed by the different types of conveyors, you need to step through the application and answer a few simple questions.
What is the product being conveyed? Describe it completely!
What type of environment will the conveyor be placed in?
The environment plays a huge factor in the decision-making process. Is it an industrial application, clean room application or a wash-down/sanitary application? Environment may dictate the conveyor choice due the material of the conveyor..
Time for an example: Ready-To-Eat Food assembly line.
Anything with non-packaged food should be considered a sanitary application. How does this affect the choice? Conveyor Material Choice. The conveyor needs to be robust, easy to clean, and durable. Stainless steel and special plastics are used to accomplish this.
How is the product presented to and discharged from the conveyor?
The goal is to minimize product loss at the transfer points.
How will it be integrated to the current process/machine?
Choosing the wrong conveyor is an expense mistake. Before buying the conveyor, you need to know how it will be integrated in the current process or added to the machine. Here is a brief list of key factors that will help you integrate it.
- Overall Dimensions
- Motor Location
- Speed
- Voltage
- Controls
Use this small list of helpful questions to guide you in the decision-making process. If you need additional assistance or have any questions, please contact us and we will be glad to help you find the right conveyor for your application.
Posted by Mark Howe on Wed, Dec 21, 2011 @ 12:50 PM
2011 is quickly coming to an end so here is a look back at our Top 5 Blog posts for the year.
- Choosing The Correct 80/20 Aluminum Extrusion for Your Application
- Five 80/20 Aluminum Extrusion Assembly Tips
- Machine Frame and Guarding | Aluminum Extrusion vs. Welded Steel
- 3 Different 80/20 Aluminum Extrusion Applications
- Automation 101 - Programming Robots Made Easy
Thank you for taking the time to read the blog posts and we hope you walked away with valuable knowledge.
Please take the time to let us know what you would like us to talk about. We have big plans for the blog in 2012, but want to make sure we are talking about topics that interest you.
Thanks again!
Happy Holidays and Merry Christmas from The Knotts Gang!
Posted by Mark Howe on Thu, Dec 08, 2011 @ 11:15 AM
Many people hear the hype about using robotics in their industrial operations with a skeptical ear. Nothing beats the human eye for making sure a product is made with the highest level of quality. This is very true in almost all cases, but having humans perform and inspect in so many areas of an industrial operation can be costly. And humans can be prone to mistakes, distractions, and sick days.
- Robotics can be very beneficial for product quality as well as more expedient production. Once programmed, a robot can perform an operation consistently with optimum accuracy and precision. Throughput speeds can increase dramatically through the implementation of robotics. And robots can run 24 hours a day, 7 days a week, 365 days a year if necessary – each time performing the same consistent operation with the same degree of accuracy and quality.
- Robots do require maintenance in order to keep them running and performing properly. But robots also provide a level of safety by handling operations where human hands or eyes could be put in harm’s way. The worker can be in a supervisory and maintenance role instead of handling intricate operations, potentially dangerous chemicals, or sharp tools.
- Finally, robotics can pay for themselves very quickly because they do not require all of the overhead that human workers require such as benefits and vacation time. It gives your company the ability to refocus your work force on your core competencies.
When looking for robotics to supplement your production operations, contact the professionals at The Knotts Company for help in determining the best solution for your business.
Posted by Mark Guida on Tue, Nov 01, 2011 @ 07:30 AM
“The hand is quicker than the eye” is an old adage from magicians and illusionists. Indeed, the human eye can be fooled from time to time. And when it comes to food processing and packaging it is important that our eyes are not fooled. With advances in vision inspection equipment, machines can help with visual inspections. This automation can greatly improve quality, safety and efficiency in a food packaging operation.
In a recent article from the International Society of Automation (ISA), machine vision technology was explained as being “more intelligent” to address food industry regulations by improving the methods for repeatable visual inspections. There are several reasons that a plant should consider vision inspection technology for their food packaging:
- Accuracy and consistency – the machine eye does not tire and is consistently reviewing using the same criteria
- Efficiency – the machine is able to inspect a substantially larger number of products in a short period of time
- Hygienic – the machine meets with FDA regulations because it never needs to come in contact with the food or package
- Cost effective – the cost to implement vision technology has greatly reduced in recent years
- Variable – the machines can be configured to be used with a variety of different types of products and packages
The machines can detect when an object is placed in front of the sensor for inspection. A camera is then triggered that can take a picture of the product and the image is then reviewed based on many criteria that is configured by the business. For example, in food packaging and processing the machine may inspect:
- Size and shape of product
- Package markings
- Read barcodes
- Read human-readable text
- Detect some defects in packaging and flag or route for human review
With the machine vision technology, the number of food items that can be inspected can increase exponentially because the camera can review individual items in a very short period of time. This allows the human inspectors time to address more serious issues.
With integration into other systems such as motion control and scheduler software, the vision inspection technology can be very useful to improve plant efficiency.
Posted by Rick Howe on Thu, Oct 27, 2011 @ 07:30 AM
John C. Maxwell quoted “Change is inevitable. Growth is optional.” This holds very true for industrial operations and the manufacturing industry. Businesses that are responsible for processing, packaging, and assembly of goods must be prepared to adjust to change in order to grow their business and adapt to new business dynamics.
New industrial automation technologies can help your business to meet these changes head on. While your plant may already have conveyors, pipes, pneumatic valves and actuators and other industrial devices, it may be time to review your equipment and determine if an upgrade or replacement is in order.
- Conveyors – newer technologies have improved conveyor systems in many ways. Conveyors can be fitted to run at variable speeds, have much easier cleaning and maintenance mechanisms, and meet very stringent federal regulations.
- Pneumatic equipment – from pipes and tubing to valves and actuators, pneumatic equipment must function reliably and safely. These pressurized components can cause serious issues if they are not assembled and maintained properly. Newer pneumatic equipment provides very sturdy and reliable materials that can last longer than older equipment.
- Motion control and automation – the newest sensors and motion software can monitor production and assembly lines in real-time. Automated routing and notifications provide the ability for the plant operations to run seamlessly and meet aggressive schedule deadlines.
There are also vision inspection systems and logic software packages available that can even further automate plant operations. The benefits to industrial automation include more reliable and predictable results, higher productivity, cleaner environment with less noise, and safer work conditions.
Before investing in any new equipment, plant managers should have a review of their operations by trained experts who understand industrial automation and can help in applying new technologies. During the audit and review, sensors can be checked, conveyors can be tested, pipes and other materials can be inspected for compliance. In addition to the equipment review, an expert should sit down and discuss the business goals and objectives. Is the plant meeting productivity requirements today? Will there be a need to increase productivity or change production lines in the future? How adaptable does the plant need to be in order to handle multiple types of products? What levels of productivity should the plant achieve in order to meet sales and profit goals?
Industrial automation can be very beneficial to businesses that need to move their current products and be prepared for changes to those products in the future. Discuss your plant’s options with a trained expert who will come up with a plan to help your business to stay ready for change and growth.
Posted by Mark Howe on Mon, Oct 17, 2011 @ 09:32 AM
80/20 Aluminum Extrusion can be applied just about anywhere. It really is only limited by your imagination. This post is going to cover three applications that we have been involved with in the past 20 years.
Machine Guarding
This isn't the supermodel of applications, but it is an extremely important application of the material. Machines have a variety of functions and most of the time we want to keep the operators limbs away from them. Aluminum extrusion is the solution. The versatility of the t-slotted design allows you to create a guard that will cover everything safely. Depending on what the function of the machine is, you can put panels or mesh inside the t-slots. Still need access? Not a problem. Add some doors with safety switches. Now the maintenance team can access various parts of the machine without having to disassemble the guard.
Here is an example of a Machine Guard:
Machine Frame
Building a machine frame out of aluminum extrusion is a great opportunity to see the full potential of the t-slot design. The modular design allows to quick adjustments or additions during the building process. Everything looks great on a computer screen or paper, but when it comes to the point of assembly some changes might be required. Aluminum is easy to cut and the t-slots allow you to easily add to the existing design. One of your concerns might be the strength and integrity of the frame. Nobody wants their frame failing at the customer. 80/20 has large 3" by 3" and 3" by 6" extrusions that will create a solid base. Choose the right fastening method and you have a frame close to the strength of welded steel.
Check out this machine frame with an integrated guard:
Movie Set
One of the coolest application we have been involved with, is helping build parts of a big screen movie set. Not the everyday application. This was a great chance to see someone really thinking outside the box. Can you name the movie?
Now ask yourself, What are you going to build with 80/20?
Posted by Rick Howe on Tue, Oct 11, 2011 @ 12:49 PM
It is becoming increasingly beneficial for both large and small businesses to outsource their non-essential operational needs. The advantages of outsourcing a company's resources are outstanding. More and more businesses are choosing to empower outside companies to handle portions of their business needs while they devote there resources toward the core competency of the company.
Cost Savings
The number one reason that a business should outsource some of it's operational needs is because outsourcing saves money. Outsourcing helps to reduce the monthly capital outlay by lowering the amount of fixed cost for your business. Cost savings are even more significant when you factor in the time it takes to maintain certain business systems. This allows your company to capitalize on other services that increase company performance.
Control of expenses
Controlling costs are a huge part of the success of any business. In general, payroll is one of the leading expenses that companies are faced with. The less people to have on your own staff, the lower your payroll expense. Outsourcing eliminates the need to have a separate department for business functions when advances in technology allow companies to access technical resources remotely.
Focus on Your Core Competency
When businesses choose to take responsibility over every aspect of their internal operations, they are also taking on the responsibility associated with those duties. Every moment that you spend attending to non-essential issues is a moment that you could have spent with a customer. However, when you outsource services to a company that specializes in your desired area, you can be reassured that your performance needs will be met. Outsourcing allows you to refocus your energy into the areas that drive your business. Outsourcing your company's non-essential needs makes it possible for you gain clarity and focus on your business without distraction. Increasing your concentration in your area of expertise is likely to drive productivity and increase your company's revenue.
Competing with Big Business
Small businesses don't have the budget or access to resources that big businesses do. Often times, managers of small businesses wind up dividing their time between addressing consumer needs and addressing operational problems. Outsourcing enables small business to compete with the pace and complexity of big businesses. When excess distractions are eliminated from small business they are more likely to meet their revenue goals.
Access to Design Resources
The need for product integration and technology has become common place in business today. Spending time developing skills outside of your company's core competency can be one of the most frustrating tasks in the world. This is especially if you are not fond of the task at hand. Today's consumers have high expectations for business. Accessing the expertise of outsourcing companies can make the difference in your company's performance and reputation.
Reliability Resources
Because outsourcing companies are not a part of the company, problems that effect your business don't necessarily effect the outsourcing company. Outsourcing companies are constantly focused on improving your business systems and attempting to enhance your ability to increase your company's performance. Outsourcing companies help to stabilize certain business processes so that they can be seamlessly executed. Consistency and seemless execution will build your company's reputation and leave a lasting impression on consumers. Having an outsourcing company in place is priceless when things in the office are going haywire.