Resources AND EXAMPLES

Project examples

Custom automated inspection and automation integration are our jam.

No job is too big, too small, too simple, too complicated, or too one-and-done. We love the challenge, and we love helping customers make their business more efficient and profitable.

Check out some of our latest projects, and then contact us to discuss your needs.

mop head inversion cell

INDUSTRY: Foam Manufacturing, Medical

SOLUTION: Orka developed a machine that inverts, or turns a mophead “outside in” after the interior edges are fused. This solution reduces waste by replacing tedious and inconsistent manual inversion. At the end of the process, mopheads are moved by conveyor, bagged, and labeled.

foam conveyance

INDUSTRY: Foam Manufacturing, Automotive

SOLUTION: This solution moves large bunks via conveyor, transporting them from a cutting station to multiple areas for further processing. The splitting action replaces labor intensive manual lifting to separate the multi-hundred pound buns after cutting.

robotic part inspection

INDUSTRY: High Pressure Fuel Rail Manufacturing, Automotive

SOLUTION: This solution moves fuel rails through a multi-station inspection process using an overhead Omron Adept parallel robot. Conditional logic moves the parts through the stations, directing them to the next station based on the testing result. It is also synchronized with upstream and downstream automated processes to ensure consistent piece flow and cycle time.

mop head assembly

INDUSTRY: Foam Manufacturing , Medical

SOLUTION: This solution crimps an aluminum channel on the end of a foam pad to create a mop head. Previously, a manual, labor-intensive and repetitive crimping process was used, with inconsistent results.

automated die casting inspection

INDUSTRY: Die Casting , Automotive

SOLUTION: This solution brings 100% inspection and traceability to the shop floor, replacing CMM and hand-held air gaging. The platform can be robotically loaded and unloaded, and incorporates air gaging and probes to perform extremely precise quality checks in less than 30 seconds. A feature for dimensional offsets/adjustments based on the temperature of parts has recently been added to the platform.

foam washer optical inspection

INDUSTRY: Foam Manufacturing , Medical

SOLUTION: Our customer was spending a significant amount of time and manpower inspecting foam washers used in medical devices for dimensions, shape/form, and surface quality. They needed an automated solution that could move them from manual visual inspection to 100% inspection at a cycle time of 5 washers per second. Orka designed and built a system that sorts and inspects the washers using four high speed cameras, and separates failures by failure type.

leg spider automated inspection

INDUSTRY: Stamping, Automotive

SOLUTION: Our customer wanted a low-cost, reliable, and durable solution for 100% inspection of a stamped leg spider. This relatively simple solution was designed to accommodate these goals using LVDTs for accuracy and durability. It repeats to 10 microns with a cycle time of less than 10 seconds, with variable data capture for analysis and tracking.

smart conveyor

INDUSTRY: High Pressure Fuel Rails, Automotive

SOLUTION: This is the next phase of an over 600 foot conveyor system being readied for installation at our customer, an automotive industry supplier in Ohio. It includes vision identification and routing, offline work cells for assembly, inspection, and rework, and lift stations to adjust the line height for attached processes. This system replaces a significant amount of manual product movement via handcarts and manual pallet forks, and eliminates receptive lifting of heavy part bins.

AUTOMATED FUEL RAIL INSPECTION

INDUSTRY: High Pressure Fuel Rails, Automotive

SOLUTION: This solution, co-developed with our sister company Component Engineering, is a high-speed in-line inspection system for high pressure fuel rails. The system captures variable data by part number for many features, including true position hole location, profiles, etc. All measurements are captured in 30 seconds or less, and stored for further analysis. Measurements are also correlated to the customer’s CMM machine for comparison and validation.

HIGH SPEED VISION INSPECT, SORT, PACKAGE

INDUSTRY: Die Cast Parts, Automotive

SOLUTION: This automated solution consists of a conveyance system that moves right hand and left hand die cast parts through a vision system that inspects for dimensions and surface defects, and sorts accepted parts into right hand and left hand boxes for taping and packaging. It processes one part every 2.5 seconds.