BlueBay Automation helps OEMs, End Users and Machine Builders design and implement technology solutions to reduce costs throughout their processes and protect their automation investments for the long run.
Application and Engineering Assistance
Electrical Engineering and Design
- Panel Layout Design
- Electrical schematics
- Adhere to NFPA 79 standards
- PLC programming
- Servo Motor Sizing and Selection
- Motion Control programming
- SCARA, Cartesian and Articulate Arm Robotics
- IIoT, SCADA and HMI
- Vision Inspection
- 3-D Solid Modeling & Drafting Services (SolidWorks & OnShape)
- FEA Analysis
- Prototyping (machining & 3D-Printing).
BlueBay Automation offers full turnkey systems integration services to provide customers with complete end-to-end solutions. Our experience in advanced automation concepts, including forward and inverse kinematics, have allowed us to supply proven solutions to difficult applications.
- BlueBay developed an extremely high-speed 4-Bar SCARA robot for an electronics manufacturer. The 4-Bar mechanism was selected due to it’s rigidity, low inertia, and ability to operate and extremely high speeds while maintaining a high degree of repeatability and accuracy. The system was built using Yaskawa Direct Drive servo motors.
- BlueBay helped to develop a Delta-2 style robot for a converting OEM. The custom dual arm D2 robot was integrated into a Yaskawa motion control system utilizing advanced electronic camming techniques. The solution allowed the OEM to achieve precise registration while picking and placing a large corrugated sheet onto a high-speed die-cutter.
- Panel Fabrication
- Industrial Control Panel Fabrication & Wiring
- Point to Point quality checking prior to power up testing
- Installation & Commissioning field services available
- Specializing in panel fabrication for OEMs as well as the Automation Industry
- NFPA 79 wiring practices
- Machine Guarding
- BlueBay Automation offers complete machine guarding solutions. Our mechanical engineering capabilities, coupled with world-class machine safety devices, allows us to provide solutions to almost all machine guarding needs. BlueBay will provide mechanical design, electrical design, and integrate the system into existing machinery.
- Machine Retrofits
- BlueBay has helped many end-user manufacturers retrofit older equipment with modern controls. In many cases, older machines are mechanically sound and can benefit from a controls system upgrade. These upgrades often result in higher machine performance and throughput resulting a cost-effective option versus purchasing a new machine.
There are several reasons to automate. However, automation is mostly seen as a means to increase production while lowering cost. Traditionally, custom machines are designed to perform a very specific task. This is known as “Hard Automation”. While Hard Automation will always have a place in manufacturing, it is generally only feasible for products that require mass production. Therefore, in many cases, it is cost prohibitive for manufacturers to employ automation where lower volumes and high product mix exist.
Here at BlueBay, we are seeing a growing demand for “Flexible Automation”. Because of the cost and flexibility limitations with Hard Automation, some manufacturers have not employed automation and continue to struggle with meeting deliveries and are finding it difficult to remain competitive in a global economy. As the costs of robots come down, and the introduction of Collaborative Robots to industry, the barrier to entry for automated cells has been grossly reduced.
The idea behind Flexible Automation is that a particular robotic cell can be adapted to multiple (often unrelated) processes. Some processes that lend themselves to automation might only require a robot to work for 3 hours per shift. It can be difficult to financially justify that automation cell in such a scenario. However, if that same cell could be easily adapted to perform 2 or 3 more tasks per day, justification in terms of ROI (return on investment) becomes much easier.
Investing in a Flexible Automation Solution is just that; an investment. Because of it’s versatility, these automation cells become assets that can be redeployed as necessary. In contrast, a Hard Automation cell requires a definitive product life cycle that must be guaranteed in order to achieve an acceptable ROI.
BlueBay offers several products that can be combined to achieve the perfect affordable Flexible Automation Cell.
- Yaskawa Motoman Robot or Precise Automation Collaborative Robot
- Any of these robots are the perfect foundation for Flexible Automation Cell. We recommend Precise Automation for any application that requires a collaborative robot. In higher speed or applications that require a higher payload, we recommend Yaskawa Motoman robots.
- Graco and Asyril Flexible Feeders
- Both Asyril and Graco are an essential component for Flexible Automation. For smaller parts, and parts that need to be oriented, we recommend Asyril. For larger parts we recommend Graco. Flexible feeders are superior to traditional bowl feeders in that they do not jam, and can handle an infinite mix of product shapes and sizes.
- Sensopart Vision Systems
- Because parts in a flexible feeder are presented in random positions, a vision system is necessary to identify what parts to pick and transmit those coordinates to the robot. Sensopart offers extremely capable, cost effective, and user friendly vision systems with built in robot calibration features for fast and reliable deployment.
Yaskawa Singular Control is a new concept allowing machine builders and Food and Beverage manufacturers a way to develop packaging lines that include PLC, Motion, Drives, Vision, and Robotics under one open standardized programming language, IEC 61131. The Singular Control concept enables the use of off-the-shelf standard control, drives, servo systems, and robotics from Yaskawa and Yaskawa-Motoman Robotics as well as other standard products that use open networks such as EtherNet/IP and EtherCAT.
Design your ideal case packing application with gantry robots, then switch to articulated robots without the need for extensive reprogramming. It’s all part of Singular Control, which eliminates the need for a separate robot controller and a specialist in robot programming. See this combined control of robots, servos and variable speed drives at work in our Singular Control automation demo, as dramatized by our Singular Control video.
The Industrial Internet of Things (IIoT) (also known as Industry 4.0) involves connecting devices and sensors together in order to gather and aggregate information and present it in a meaningful and useful way.
Traditionally this has been the job a of localized SCADA (Supervisory Control and Data Acquisition) system. An IIoT solution can be stand alone, or be a part of an existing SCADA. The overall goal of an IIoT system is to notify personnel of alarm conditions and to have access to historical data in order to analyze and given process. Ultimately this allows maintenance personnel to respond and take corrective actions quickly to an alarm condition. Providing business executives access to real-time production data can help to identify areas for possible cost savings.
Recent advances in cross-platform interoperability have made it much easier and less expensive to deploy an IIoT solution. Historically, it was always a challenge to share data from industrial controllers and sensors due to proprietary and industrial specific protocols. Now, this is much simpler with through OPC UA and MQTT for example. These IIoT protocols are extremely efficient and offer a low payload (especially important for edge connected devices that might be on a cellular network).
There are several strategies to consider when considering an IIoT solution. BlueBay can help to determine the right fit for a given application. Some factors that would influence a decision might include
- Cellular vs local LAN/wifi (or a combination of both)
- Web cloud vs local cloud hosted
- Email and SMS notification capability
- Monitoring with our without remote control capability
IIoT can be confusing but BlueBay is able to provide solutions to most applications. It is important to note that IIoT is not solved by a single device. A carefully designs system including software and hardware solutions from our trusted partners are what make up a successful IIoT installation. Below is a representation of key BlueBay IIoT partners.
- Exor America (HMIs and dedicated IIoT devices)
- Red Lion Controls (HMIs, ethernet switches, cellular modems and routers, dedicated IIoT devices)
- Wago (PLCs with specific IIoT protocol support and industrial I/O)
- Open Source Hardware (Raspberry Pi, Beaglebone)
- Open Source software (Linux, Mosquitto MQTT Broker, SQLite, MySQL, Node-Red)