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How can you use electromechanical systems to increase productivity and reduce costs in manufacturing?

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Electromechanical systems are devices that combine electrical and mechanical components to perform various functions, such as sensing, actuating, controlling, and communicating. They are widely used in manufacturing to automate processes, improve quality, enhance safety, and optimize resources. In this article, you will learn how you can use electromechanical systems to increase productivity and reduce costs in manufacturing.

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Fabian David Hermansyah

Sales Engineer at PT. Himalaya Everest Jaya | Ex - Festo Indonesia | Power Transmission, Manufacture, Automation

1 Benefits of electromechanical systems

Electromechanical systems offer numerous advantages for manufacturing, such as greater precision and accuracy, faster speed and response, lower maintenance and energy costs, and greater flexibility and scalability. These systems can perform tasks with more accuracy than manual or hydraulic systems, leading to fewer errors and waste. Additionally, they can operate at higher speeds and adjust to changing conditions more quickly than other systems, increasing throughput and efficiency. Moreover, electromechanical systems require less maintenance and consume less energy than hydraulic or pneumatic systems, resulting in cost savings and reduced environmental impact. Finally, they can be easily configured and reconfigured to suit different applications and requirements, allowing for more customization and innovation.

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2 Types of electromechanical systems

Electromechanical systems are widely used in manufacturing, and the type of system used depends on the function and environment. Motors and drives, for instance, are devices that convert electrical energy into mechanical motion, such as rotating or linear motion, and can be used to power machines, conveyors, robots, and other equipment. Sensors and switches detect and measure physical parameters like temperature or force, while actuators and valves convert electrical signals into mechanical actions like opening or closing. Finally, relays and contactors switch electrical circuits on or off or transfer electrical power from one circuit to another. All of these systems can be utilized to monitor and control processes, ensure quality, protect circuits, isolate loads, or control devices.

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Fabian David Hermansyah

Sales Engineer at PT. Himalaya Everest Jaya | Ex - Festo Indonesia | Power Transmission, Manufacture, Automation
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The integration of IoT and smart manufacturing in electromechanical systems boosts capabilities. IoT gathers real-time data from embedded sensors, offering insights into performance and maintenance needs. Smart manufacturing uses this data for predictive analytics, enabling maintenance schedules, process adjustments, and remote control. This fusion enhances productivity, reduces downtime, and empowers agile and efficient operations in an interconnected industrial environment.

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3 Design considerations for electromechanical systems

When designing electromechanical systems for manufacturing, several factors must be taken into account. Performance requirements, such as speed, torque, force, accuracy, resolution, range, and feedback need to be defined. Additionally, the environment must be considered in terms of temperature, humidity, vibration, noise, dust, corrosion, and electromagnetic interference. Safety is also a key concern; the system must comply with relevant standards and regulations (e.g. UL, CE, ISO, OSHA and NFPA) and safety features (e.g. guards, interlocks, emergency stops and alarms) should be implemented. Finally, cost must be balanced through the selection of materials and components as well as installation, maintenance energy and waste costs.

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Fabian David Hermansyah

Sales Engineer at PT. Himalaya Everest Jaya | Ex - Festo Indonesia | Power Transmission, Manufacture, Automation
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??KEEP IT SIMPLE AND ALWAYS REMEMBER THE MANUFACTURING GOAL?? Often in the field, I find many manufacturing machines are overly complicated, resulting in unnecessary costs. For instance, choosing a power transmission gearbox with a larger frame size to avoid shockloads, while it could be replaced using an inverter or a slow starter. Using a system that aligns with standards and safety procedures is crucial, but it should also align with the primary purpose of the equipment. Every operator or engineer must be briefed regarding system design and parts replacement to avoid unnecessary issues.

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4 Best practices for electromechanical systems

To use electromechanical systems effectively and efficiently in manufacturing, you should follow some best practices. Selecting the right components is essential, as they should match the specifications and requirements of the system, and be compatible and interoperable with each other. It is also important to optimize the layout and wiring, arranging components in a way that minimizes space, length, and complexity of the wiring. Testing and troubleshooting the system is also necessary to verify functionality and performance before and after installation, as well as identify and resolve any issues or errors. Finally, monitoring and maintaining the system involves regularly inspecting and cleaning components, replacing or repairing worn or damaged parts, and using data and feedback to evaluate and improve the system.

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5 Examples of electromechanical systems in manufacturing

Electromechanical systems are widely used in various manufacturing sectors and applications, from automotive to aerospace and medical to food. In the automotive industry, they are used to assemble, test, and inspect vehicles and parts, such as engines, transmissions, brakes, and airbags. Aerospace applications include the manufacture, launch, and control of rockets, satellites, and aircraft components like wings, fuselages, landing gears, and propellers. Medical electromechanical systems produce, operate, and monitor medical devices and equipment such as pacemakers, ventilators, scanners, and pumps. Finally, food production relies on electromechanical systems for processing, packaging, and labeling food products and ingredients like meats, dairy products, grains, and beverages.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you use electromechanical systems to increase productivity and reduce costs in manufacturing?

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1 Benefits of electromechanical systems

2 Types of electromechanical systems

3 Design considerations for electromechanical systems

4 Best practices for electromechanical systems

5 Examples of electromechanical systems in manufacturing

6 Here’s what else to consider

Mechanics

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How can you use electromechanical systems to increase productivity and reduce costs in manufacturing?

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4

5

6

1 Benefits of electromechanical systems

2 Types of electromechanical systems

3 Design considerations for electromechanical systems

4 Best practices for electromechanical systems

5 Examples of electromechanical systems in manufacturing

6 Here’s what else to consider

Mechanics

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