KUKA Robot Support by E Tech Group Gets Glass Manufacturer Back on Track
After the original equipment manufacturer left work unfinished, a specialty glass manufacturer reached out to E Tech Group for help. The project required KUKA robotics experience and units for inspection delivered within a tight timeline.
The Project: Clean Up Someone Else’s Robotics Mess
The decision of who to hire (and trust) for an automation project is critical. A quality partner will focus their knowledge, techniques, and skills to meet your project needs on-time with the highest-level of client communication and customer satisfaction. After an original equipment manufacturer (OEM) left work at a specialty glass manufacturer unfinished, the manufacturer needed to quickly pivot to a new robotics automation partner that could fully support their complex project within a tight timeline.
The Solution: Leverage E Tech Group’s Experience with KUKA Robots
The E Tech Group team promptly identified the specialty glass manufacturer’s situation. The project required KUKA robotics experience to support automotive windshield applications and had additional complexities of delivering units for inspection. Challenges faced were a tight timeline and conferring with overseas decision-makers.
“At E Tech Group, we have a people-focused culture,” said an E Tech Group sales team representative. “That means purposefully building authentic relationships through empathy, understanding, and respect. We apply this people-focused culture from the first phone call with potential customers so we can learn about their challenges and diagnose how we can use our unique skills to be a successful partner.”
After identifying the specialty glass manufacturer’s situation, E Tech Group deployed their Senior Controls Engineer with advanced robots training to tackle the KUKA robot challenges on-site within the same week. He applied his expertise in advanced robotics to quickly learn the OEM’s code and KUKA software, as well as understand the pattern needed for the robot to function properly for the manufacturer’s automotive applications.
The Results: On-Site KUKA Support Resolves Robot Issues
E Tech Group’s Senior Controls Engineer committed a week and a half of time on-site to resolve the robot’s functionality challenges. Dedicated to the success of the project, E Tech Group’s Senior Controls Engineer stayed into the later hours to provide support as needed and ensured the robot was functioning perfectly. The project timeline was met on-time and as promised for the KUKA robot to apply epoxy to windshield sensor units.
E Tech Group foresees more opportunities to support projects like this in the future based on the success of this project and its quick turnaround time with oversees decision makers. “This was an exciting opportunity for us to apply our experience. Our Senior Controls Engineer has worked all over the globe and we believe E Tech Group has value to offer beyond our domestic borders” said an E Tech Group representative. “The more we can grow organically with customers, the more we have to offer.”
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Challenge
Acting as the brain behind industrial operations, PLCs are designed to perform logical decision making for control applications. But, what should be done when a PLC system reaches the end of its life cycle? This case study explores how E Tech Group supported the PLC upgrade for a carbon fiber manufacturer. The customer faced the challenge of modernizing their outdated control system which included control panels operating with an Allen-Bradley PLC-5 controller and other legacy hardware. This system was used to control their traction drive process which included VFD controls for multiple motors. The customer wanted to improve their process by upgrading their control, visualization, and machine safety systems, and sought E Tech Group’s expertise to navigate the complexities of this upgrade and seamlessly transform their outdated system with a modern solution.
Solution
E Tech Group designed a plan that fulfilled the customer’s specific requirements and adhered to a tight completion timeline. The customer needed upgraded control panels with new PLC, HMI, and VFD components, alongside a modernization of their existing machine safety system to align with the latest industry standards. The project team carefully assessed each system slated for enhancement, gaining a comprehensive understanding of the customer’s existing system and their other production lines. This supported the factory acceptance testing phase, ensuring the components and controls worked properly according to the functionality of the equipment.
With proof of functionality, quality and integrity in place, the project team swiftly deployed the required upgrades which included build-to-print control panels, an Allen-Bradley PLC-5 to Rockwell Automation Compact GuardLogix controller migration, POINT Guard safety-rated I/O module configuration, Panel View Plus programming, and PowerFlex AC Drives to improve the system’s flexibility and performance.
Results
The project was successfully completed in less than 90 days, with two months dedicated to development and two weeks allocated for commissioning. E Tech Group utilized the expertise of multiple control engineering experts for this project, and effectively leveraged their experience to meet the customer’s tight completion timeline. As a result of the upgraded system, the customer experienced substantial enhancements in productivity, increased reliability, simplified system maintenance, and a user-friendly interface. The project not only met the customer’s requirements but also delivered tangible benefits to improve overall operations.