Industrial Automation Systems

Phoenix Control Systems Ltd work in all areas of industrial automation within the fields of controls, panel building, PLC/SCADA, and robotic system integration. With many years supplying a vast range of industries worldwide with quality systems we have expertise in all aspects of industrial automation.

automation of production systems

Turnkey Project

  • Quoting and project planning
  • System design
  • Panel manufacture and system pre-install
  • Buyoff with mod build trials
  • Mechanical and electrical installation
  • Commissioning and testing
  • Trajectory programming
  • Production trials
  • Training
  • Documentation
  • Production standby
  • After-sales service
control system integrator

Control Panel Builder

  • Consultation to fix the scope
  • Electrical design
  • Production of schematics
  • Procurement of panel components
  • Panel manufacture
  • Panel testing
  • Site installation
  • Site trials
  • Documentation
  • After-sales service

Software Design

  • Consultation for the creation of the functional design spec
  • Reference to FDS and schematics
  • Program structure design
  • HMI and SCADA design
  • Simulations built up
  • Simulation testing
  • Program creation
  • Transfer to PLC or robot
  • Commissioning & Production trials
  • Documentation customer support
  • Standby support off/on-site & training

There are now very few manufacturing companies that aren’t touched in some aspect by automation. From the large car manufacturers to SMEs all are looking to develop and improve their competitiveness with increases in production, in quality allied with reductions in waste, cycle times and rejected parts.

Robots in Manufacturing

Top Advantages of Manufacturing Robots

  • Robotic system integration can dramatically improve your product quality with high consistency and repeatability.
  • Robotic automation can increase production levels.
  • Robot Arm can work 24hr/day without taking breaks or vacations.
  • Robotic systems increase workplace safety, the workers are moved to the supervisory roles where they do not have to perform dangerous applications in hazardous settings.
  • Robot arm reduce costs (healthcare and insurance savings)
  • Robots take over the monotonous and tiring repetitive jobs that humans do not enjoy.

We provide robotic system integration solutions for all automated manufacturing processes.  Click for more Robot Integration news.

Five Top Car Manufacturing Robots

Robots have been used for car manufacturing for many decades now and robots are used in practically all aspects of a car build program.

Some of the most common car manufacturing robot applications, for example, are:

  1. Painting
  2. Welding
  3. Handling
  4. Hemming
  5. Glueing

As a robot integrator with a global client base, we understand the importance of the quick return on investment and cost-saving.

Read More: Five Reason to use Robots in Car Manufacturing

The manufacturing process in Aerospace

Traditionally the aerospace industry has been slow to take up new technologies within it’s manufacturing processes but now we see that robotics occupy an important role.  Not surprisingly, we see that aerospace manufacturing processes are now using industrial robots in applications that were not considered many years ago. Therefore, we see that robots in aerospace are now performing more complicated tasks with the aim of increasing levels of production.

Read more: Common Robot applications for Aerospace Industry

The plastics industry brings new opportunities and will continue growing in the future economy, largely due to the fact that plastic products are lightweight, versatile, lead to design freedom, and are suitable for large scale production and are easily recyclable.

Machine Tending Solution

Robots form an excellent solution for machine tending the plastic moulding machines used to produce the parts. Also, they display manoeuvrability and repeatability allied with a small footprint ideal for this task.

Read more: Most common robot application for Plastic Industry

Robot Applications for Pharmaceutical Industry

  • Industrial robots are found integrated into production facilities with wet-chemical surface treatment processes.
  • Robots are particularly suited to machine tending applications for Injection moulding machines producing medical devices.
  • Outstanding accuracy, make robots ideal for high-precision machining for polishing of orthopaedic implants.
  • High-speed delta robots are an excellent tool allied with a vision system for handling small objects distributed by conveyor.

Read More: Applications for the Pharmaceutical Industry

Industrial robots make excellent workers in areas where humans cannot go

More and more robots are being used in the decommissioning of nuclear power plants with their excellent resistance to radiation. For instance, robots reduce the volume of waste by mounting with large spindles or saw blades. Thereby, a wide range of materials employed within a reactor is reduced by cutting the type B waste into much smaller parts allowing the decommissioning process to be undertaken more effectively.

Read More: How robots can help the environmental industry?

The benefit of  Robot Systems for the Film Industry

  • Robots will reproduce moves with high accuracy aiding multiple takes.
  • Easy and precise translation from VFX output or Pre-Vis makes it easier to achieve the desired movement.
  • The reset time for a move is in the order of seconds, saving valuable camera time.
  • Robots offer the possibility of more dramatic and complicated moves in comparison to the traditional “tuning fork” manipulation.

Stunts and effects 

In reality, the search for more and more exciting and ambitious stunts and effects means that we will see even more significant numbers of robots employed in an ever-broadening and imaginative range within the entertainment industry.

Interestingly we find film industry robots equipped with cameras, set pieces, and innovative end effectors for entertainment both in front of the camera and behind the scene. Furthermore, we provide complete robotic system integration solutions in all industries, contact us for your next project.

Read More: Robotic special effects projects

Robot Cell Design

We integrate and install complete robot automation package solutions from initial design and consultation through to commissioning and production whether you decide to install a cell using new robots or reconditioned robots.  Call Us Now! at 01235 823120

Robot Applications

Quick Return on Investment

Employing an industrial robot can have a big impact on cost savings over manual labour over the lifetime of a project. Although sometimes small and medium-sized companies are sceptical about the use of robotics in their processes, large manufacturers are already taking advantage of this technology and reducing their waste and costs.

Therefore as a robot integrator, we are helping robotics users with the calculation of the value of the robotic investment. So, why not check out How much do industrial robots cost? So, you can get a look into how robots could be helping industries like yours.

For milling operations, the robot has a spindle as its end of arm tooling and invariably will have an automatic tool changer to allow exchange from a tool rack for different cutters.  Also, users require CAM software such as Sprutcam, Robotmaster or Powermill to create the tool paths.  Then, the robot milling software will generate the tool paths in the offline simulation to check for reach, collisions and singularities. The operator will then load the resulting tool paths into the robot.

One big advantage over traditional CNC milling machines is that you get a large working envelope for a smaller financial outlay. Also, when allied with an integrated turntable a six-axis robot can mill in all degrees of freedom allowing the cutting of complex shapes.

Read more: Top 5 Benefits of Robotic Milling

Robotic welding helps companies gain a competitive advantage over those companies that have not made the transition to welding automation. In fact, robot welding is becoming increasingly attractive for job shops.

Welding with a robot provides very high consistency of weld due to the high repeatability of the robot path. This brings improvements in quality and reduction in waste without any impact on the overall time to carry out the welding operations. In conjunction, welders can oversee the productivity of more than one robotic welding cell at a time.

Read more: Benefits of Robotic Welding Systems

Robotic cutting and trimming is a robot application where the material is removed to follow a predetermined path, for example, removing the excess from a plastic thermoformed part. Furthermore, as robots have very high path repeatability they can improve quality over manual trimming allied with an increase in production due to reduced cycle times.

Examples of the materials handled by robots are fibreglass, composite materials, metal (flash removal from casting) wood and foams.

Read more: Benefits of Robotic

Material handling robots eliminate the need for manual labour to perform lifting tasks, for example, moving, sorting, optimising among others.  Furthermore,  material handling robots are very effective at carrying out repetitive tasks especially when the operator needs to lift up a high payload.

Thereby, increasing production and avoiding tiring tasks for the staff. So, they can assist in improving business process efficiency at low operational cost.

Read more: Elements to consider in material handling operations 

Assembly robots are well known for their speed, flexibility and accuracy. Robots perform tasks in very demanding sectors such as the car industry working sequential assembly tasks as a complete production line. Also, assembly line robots can use a vast array of different end of arm tooling, achieving assembly tasks ranging from insertion of screws and rivets to glueing applications.

Our vast expertise in robotic engineering can provide the right solution for your project.  Contact Us.

Palletising robots build up layers of products for shipment usually onto pallets. When the pallet is full the operator will remove the completed pallet. Palletising products are often very heavy, for example, bags of product weighing up to 50Kg. In the case of a human worker this work will be very tiring and potentially could affect their health. However, for a robot, this poses no problem as the robot can work 24/7 non-stop if necessary.

Read more: Palletising Robots

Robotic dispensing allows for very controlled path following, allowing the laying down of beads of the product with great accuracy. Allied with a controlled dispensing system the robot can very accurately control the quantity of material dispensed via a direct interface. Also, this interface allows for changes in flow rate to be carried out in synchronisation with the robot path.

Read more: Top 5 Benefits of Dispensing Robots

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