Automation Machine Design for Manufacturers

Why automation projects stall, and how design prevents it

Manufacturers automate to cut cycle time, labour variation and rework. Projects stall when the mechanical design does not match the real process: parts arrive in unpredictable orientations, grippers are not designed for the actual tolerance range, or actuators run at their limit and become unreliable. LTM designs automation machines from the part and the process outward, so the equipment handles real production variation, not only the nominal drawing.

Automation machines we design

• Pick and place units, gantries and rotary indexing tables
• Automatic feeders, escapements, magazines and part orientation tooling
• Assembly fixtures, pressing stations and screwing stations
• Loading, inspection and reject cells, such as our valve loading and inspection cell
• Robot cell structures, risers, part presentation and guarding
• Retrofits that add automatic loading or feed axes to existing machines

A typical automation project

Consider a manual operation where an operator loads a part, clamps it, runs a process and unloads it, at around 40 seconds per part. A typical first step is a semi-automatic station: automatic clamping and processing with manual loading, which often cuts cycle time by a third and removes most quality variation. The next step adds automatic loading from a feeder or magazine, so one operator can run several stations.

LTM designs each step so it can be extended later. The frame, mounting points and controls space for the automatic loader are included in the first design, so moving to full automation is an addition, not a rebuild. This staged approach lets manufacturers prove the process and the payback before committing to the full investment.

Design considerations specific to automation

Cycle time: every motion is timed with realistic acceleration and settling, and the sequence is checked for overlap opportunities. Repeatability: locating schemes use proper datums and hardened locators so position does not drift with wear. Changeover: change parts are keyed and quick to swap where several variants run on one line. Maintainability: wear parts, sensors and valves are reachable without dismantling the machine. Safety: guarding, interlocks and operator access are laid out with the machine, not added afterwards.

Indexing and servo axes sized correctly

Rotary indexers and servo axes are a common source of trouble when inertia is underestimated. We calculate load inertia from the 3D model, check the inertia ratio and RMS torque over the full motion profile and select gearboxes for backlash and life. You can see the same method in our free servo motor sizing calculator and check gear stages with the gear ratio calculator.

Who we work with

Automation integrators who need mechanical design capacity, SPM builders, and manufacturers in automotive components, electrical equipment, valves and pumps, packaging and general engineering. Work is delivered remotely in Autodesk Inventor or SolidWorks with drawings your local fabricator can build from.