Design Approaches for Non-Standard Automation: Even Beginners Can Understand | Say Goodbye to Drawing and Guessing

Customised AutomationDesign Concepts Even Beginners Can Understand | Say Goodbye to Drawing Without a Plan

Many newcomers to the non-standard automation industry share the same dilemma: when faced with a request for quotation, their minds go blank, and they are only able to copy existing drawings verbatim; even a minor modification to a product leaves them unable to carry out the design work.

As someone who has worked as a non-standard structural engineer for three years, I can honestly say that there is no ‘mystique’ to non-standard design; all equipment is designed according to a fixed five-step process, There is no need for advanced knowledge of mechanics, nor is it necessary to memorise a vast number of standard components; even someone with no prior experience can understand and master it, and after studying it, they will be able to devise a solution independently.

Firstly, we must dispel the misconception that ‘non-standard’ does not mean designing haphazardly as one pleases. ‘Non-standard’ means that, building upon standard modules, standard cylinders and standard conveyor lines, the dimensions, workstations and movements are adapted to suit the customer’s product; Ninety per cent of the structure reuses standard components, whilst only ten per cent requires custom machining.

Step 1: Dive deep into the product and get to grips with the three core parameters (80% beginners often struggle at this stage)

Whatever you do, don’t start drawing straight away! First, take a sample of the client’s product, clarify three key points, and jot them down on a scrap of paper:

What are the characteristics of the product? Is the material soft or hard? Is it prone to deformation? What exactly are the dimensional tolerances? For instance, plastic parts must not be gripped too firmly; aluminium parts require a polyurethane pad when clamped; and thin sheet products must not be pressed too hard with ejector pins. Many instances of material jamming or workpieces being damaged during later stages of production are caused by a failure to check the product’s material properties at the outset. The process sequence is as follows: what steps does the customer need to carry out? First comes loading, followed by positioning, then clamping, then machining or inspection, and finally unloading. This sequence must under no circumstances be altered. For example, when checking dimensions, positioning must be carried out first; one must not clamp the workpiece before positioning, as this will directly cause dimensional deviations. The production capacity requirement is: how many parts per minute does the client require? Production capacity directly determines the layout of the equipment. For a single-station setup, a rate of up to five parts per minute is sufficient; however, if the rate exceeds 20 parts per minute, a multi-station layout incorporating a turntable or assembly line is essential. Blindly adopting a multi-station setup will only unnecessarily increase costs.

Industry saying: Once you’ve fully grasped the product, half the solution is already done.

Step 2: Break down the movements—divide complex processes into individual mechanical movements

Any piece of automated equipment, when broken down to its simplest form, consists of only six basic movements; there is no seventh. These are: lifting, translation, rotation, clamping, ejection and flipping.

To give a simple example: a machine for applying foam to mobile phone cases

Original process: Pick up the sponge → Move it to the top of the mobile phone case → Press down to adhere → Release and return to the starting position

Following disassembly, the process begins by using a suction cup to grip the sponge for clamping, followed by translational movement achieved using a linear actuator, then vertical movement using a slim-profile pneumatic cylinder, and finally returning the module to its home position to reset the system.

General tips for beginners: Whenever you come across a complex piece of equipment, break it down into these six steps. Don’t try to use a single mechanism to perform multiple functions—the more complex the design, the more likely it is to malfunction, and the after-sales service can be a real headache.

Step 3: When selecting components, give priority to standard parts; opt for off-the-shelf items rather than custom-made ones wherever possible

A common mistake made by beginners is that they are keen to manufacture parts themselves, believing that the precision of their own designs is higher. In reality, however, there is a rule in the non-standard parts industry: when standard parts are sourced externally, the failure rate is lowest, delivery times are shortest, and prices are the most competitive.

A realistic picture of the industry: In a typical non-standard piece of equipment, standard components account for 75%, whilst custom-made sheet metal and specialised jigs account for only 25%; 90% of a senior engineer’s time is spent arranging standard components rather than drawing up plans.

Step 4: Spatial layout – follow the three golden rules

Once you have finalised your structural design, move straight on to the overall layout of the aircraft. Bear in mind these three principles, which can be applied without a second thought; this will ensure that no interference or collisions occur.

Arrange the components from top to bottom: the upper layer carries out the operational actions, which include gripping and inspection; the middle layer is responsible for product flow; and the lower layer comprises electrical wiring and pneumatic piping. Ensure that no pipes or cables cross the moving structures, and that the clearance for movement is greater than or equal to 5 mm. Beginners are particularly prone to causing interference. For all moving and fixed parts, a minimum clearance of 5 mm must be allowed; do not operate at the absolute limit, as assembly tolerances will inevitably cause interference. Priority must be given to ease of maintenance. Wear-prone components, such as suction cups, sensors and bearings, must all be positioned on the exterior of the equipment so that they can be replaced without dismantling the machine. During customer acceptance, the primary consideration is the ease of maintenance. The fifth step is to incorporate fail-safe measures—this is a critical design feature that novices most commonly overlook.

Compliant non-standard equipment must incorporate fault-tolerant design to cope with defective incoming materials: