Automation of a deburring machine

BUSINESS CASE: The automation of your industrial processes can offer both economical and physical opportunities for your company and your employees. In this business case, we will show the benefits for a company that decides to automate a deburring machine by Teqram. In this specific case a machine to round edges.

The following example information used for this test:

  • Maximum weight of product is 125 kg.
  • Distance between products: 100 mm (in length and width).
  • Dimensions of products to deburr: between 150 x 150 mm and 1300 x 1300 mm.
  • Throughput capacity (values for high quality single side deburring):
    • Radius 0.5mm == 1200 mm/Min
    • Radius 1.0mm == 1000 mm/Min
    • Radius 1.5mm == 500 mm/Min
    • Radius 2.0mm == 300 mm/Min

Max. amount of products for a 0.5 mm radius.

Product dimensions 150 mm 300 mm 450 mm 600 mm >750 mm
Steel thickness (mm) 5 10 15 20 25
Product weight (kg) 0,9 7,0 23,7 56,2 109,7
Amount of products next to eachother 6 3 2 2 1
Products per hour (double side) 144 90 65 51 42
Kilograms per hour (handling) 254 1.264 3.102 5.776 9.291
Yearly per 1800 hours / 1 shift 259.200 162.000 117.818 92.571 76.235
Yearly per 5400 hours ( 3 shifts) 777.600 486.000 353.455 277.714 228.706

Preliminary conclusion:

  • Even for lightweight products (ie. deburring steel plates up to 25 kg.) the physical load is considerable (>3 Tonnes per hour for loading and unloading).
  • To reach these amounts, 2 employees per shift will be needed. (even for a double side deburring machine).
  • Secondly, every employee will need a swivel crane.
  • Double side deburring machines offer a lower quality than single side deburring machines.
  • From a quality point of view, the best choice is a single side deburring machine. Every product will be put through the machine two times (each side once).
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    Comparison of investments.

    To calculate the costs and gains of an investment in robotizing a deburring machine, a comparison is made between a regular deburring machine and a deburring machine equipped with our easyEye®.

      Double side deburring machine + 2 swivel cranes Single side deburring machine + 2 robots
    Machine investment €220.000 €130.000
    Robot investment €0 €260.000
    2x swivel crane €20.000 €0
    Total investment €240.000 €390.000

    Looking at just the investment, deburring metal with a regular machine without our easyEye® is cheaper. However, a calculation of the total costs shows different:

    Excl. electricity, wear and maintenance costs Double side deburring machine + 2 swivel cranes Single side deburring machine + robots
    Write-down (7 years) €34.000 per year €56.000 per year
    Labor costs 1 shift per year 2 x €40.000 = €80.000 0.5 x €40.000 = €20.000
    Labor costs 3 shifts per year 3 x €80.000 = €240.000 3 x €20.000 = €60.000
    Yearly costs for 1 shift €80.000 + €34.000 = €114.000 €56.000 + €60.000 = €116.000
    Yearly costs for 3 shifts €240.000 + €34.000 = €274.000 €56.000 + €60.000 = €116.000

    The diagram shows that mechanical deburring in shifts result in higher total costs compared to industrial automation of a deburring machine with the automation technology by Teqram. The biggest difference is in labor costs. These decrease significantly by using two easyEye® robots. Secondly, the use of two robots saves the costs of buying two swivel cranes and takes away physical load on employees when loading and unloading the machine.

    Conclusion

    • The investment for a single side deburring machine + easyEye® robot results in significantly higher costs than investing in a double side deburring machine + swivel cranes.
    • For smaller companies, the best choice is to go for a regular deburring machine.
    • Companies that are using shifts for deburring, could save a lot of costs by using one or more easyEye® robots to automate deburring processes.
    • A big advantage of automating is the higher quality that single side deburring will give.
    • Yearly savings are especially high when two or more shifts could be replaced by a fully robotized deburring machines.
    • More than 150.000 euros per year could be saved by replacing 3 shifts for a fully automated deburring machine.