Industrial machine design - a comprehensive step-by-step guide

Estimated reading time: 10 minutes

TL;DR:

• Properly designed industrial machinery increases a company's productivity and competitiveness.
• The design process includes needs analysis, 3D modelling and prototype testing.
• Automation and robotisation are streamlining key stages of production.
• Compliance with safety and ergonomic standards is the basis for trouble-free operation.
• Choosing an experienced engineering partner minimises risk and produces better results.

Table of contents

• Introduction
• Industrial machinery design - why is it a key part of business development?
• What is industrial machinery design?
• Main stages of machine design
• The role of automation and robotisation in machine design
• Key standards and regulations (safety and ergonomics)
• Machine design in practice - expert advice
• Examples of applications in various industries
• Summary of top tips
• Completion
• FAQ

Introduction

Industrial machinery design is an extremely important process in today's industry. The efficiency, safety and profitability of production depends on properly designed and manufactured equipment. In this article, we will explain the step-by-step process of industrial machinery design, what benefits it can bring to a company and what to look out for to avoid the most common problems. You will also learn how setting up the right automation and possible robotisation affect the final results and where to look for support.

Industrial machinery design - why is it a key part of business development?

In an era of intense industrial development and increasing competition, companies are looking for solutions to increase production efficiency, reduce costs and improve product quality and employee safety. This is where industrial machine design plays a huge role. A well-designed and integrated production line provides:

• Reducing production cycle times.
• Minimising material losses.
• Reducing labour costs by eliminating repetitive human activities.
• Improving the quality of manufactured products.
• Strengthening the company's competitiveness in the market.

Safety and ergonomics are equally important. Poorly designed equipment can result in malfunctions, downtime and even accidents, which have a negative impact on the company's image and lower staff morale.

What is industrial machinery design?

Industrial machine design is a multi-step process that combines knowledge of mechanics, automation, robotics, electronics and control system programming. It encompasses both structural aspects (material selection, strength calculations, ergonomics, applied processing technologies) and issues related to the integration of machines into an existing production environment. Increasingly, vision systems, MES/ERP control systems or collaborative robots (so-called cobots) play an important role during design.

This process can range from the design of single stations to entire lines or even complete implementations of robotic solutions. At Michale Automatika, we have specialised for years in the creation of modern machines and automated lines for the needs of specific production facilities.

Main stages of machine design

The following are the key elements that make up the complex design of industrial machinery. Being aware of these stages allows you to make informed decisions, control the progress of the work and make sure the project is heading in the right direction.

Needs analysis and planning

The most effective projects begin with an in-depth analysis of the client's needs. At this point, understanding is key:

• What functions and tasks does the machine have to perform (e.g. welding, packaging, assembly, machining)?
• What are the capacity requirements of the machine (e.g. number of pieces per hour)?
• What standards and regulations apply to the industry (including health and safety and specific quality standards)?
• How will the machine integrate with existing production processes?

Designers often participate in visits to the production plant, where they observe processes and interview decision-makers. At this stage, the budget, the scope of the project (e.g. whether only a machine is involved or the entire line will need to be implemented), and an approximate schedule are determined.

Conceptual design and 3D modelling

Once the assumptions have been established, it is time to prepare the initial concepts. Designers usually create hand-drawn sketches or simple visualisations in graphic programmes to better illustrate the planned solutions. The next step is advanced 3D design:

• Engineers are assisted by CAD software to create highly detailed models of components and mechanisms.
• Key components such as motors, actuators, sensors, control panels or safety features are deployed.
• A first visualisation of the appearance and operation of the device is created.

It is important to consider ergonomics of operation, worker safety and technological requirements for each modification. The 3D design is also used to present the concept to the customer - this stage is iterative, meaning that many adjustments may need to be made before the final appearance and mechanics of the machine are accepted.

Strength analyses and simulations

Once the concept is accepted, care must be taken to check the mechanical solutions in detail for strength and performance. The following is then applied:

• Finite element method (FEA/FEA) to analyse stress and strain distributions in key parts of the structure.
• Simulations of the motion and dynamics of systems (e.g. power transmission mechanisms).
• Sometimes testing of part prototypes (especially when there are harsh environmental conditions, such as high temperatures).

The simulation results may result in a decision to select other materials, change profile cross-sections or reinforce critical points in the structure. For machines built in series production, optimising the design to reduce material consumption can be extremely important.

Creation of technical documentation and control systems

Once the main design principles have been approved, it is time to prepare the official documentation:

• 2D drawings (with dimensions, tolerances and machining requirements).
• Material specification and parts list (including commercial items).
• Electrical diagrams (design of PLC controls, cabling, sensors, control panels).
• Safety specifications (e.g. what safeguards or emergency stop systems will be used).

At Michale Automatika, our experienced engineering staff has been involved for years in both the preparation of mechanical designs and the creation of professional control systems tailored to specific needs. This provides our customers with comprehensive support.

Prototype construction and testing

Once the documentation has been completed, the stage of actually building the device begins. Depending on the complexity of the project, this may first be a prototype or directly the final model. The next steps are:

• Purchase of materials and commercial items as listed in the documentation.
• Production of mechanical parts, e.g. on CNC machine tools (lathes, milling machines, grinding machines).
• Mechanical assembly and installation of the control system (connection of cables, sensors, HMI panel).
• Initial commissioning (so-called start-up).

During the testing phase, it is verified that all parameters are working as intended. Possible adjustments are made, e.g. adjustments to the PLC control programme or changes to the initial drive settings. If all goes well, the machine becomes ready for transport and implementation at the customer's site.

Implementation and integration on site

Even the best-designed device will not deliver the expected benefits if it is not properly integrated into an existing production sequence. Implementation includes:

• Transport of the machine to the customer's premises and its foundation at the indicated location.
• Connection to the necessary utilities (electrical supply, compressed air, purification systems, etc.).
• Integration with already functioning workstations or lines (e.g. exchange of signals with the ERP/MES system).
• Acceptance testing and confirmation that the unit achieves the intended performance and safety level of operation.

For more complex processes, consider further automation, including the use of industrial robots. You can find out more about the solutions available from us by visiting the Services of Michale Automation.

The role of automation and robotisation in machine design

Today, many industries are relying on automated and robotic lines to increase competitiveness and meet increasing demands. Automation can involve simple stations (e.g. feeding parts) or advanced systems with a range of robots and vision sensors. At Michale Automation, we assist in the selection and integration of industrial robots so that they work with the machine from the design stage.

• Robotisation of packaging or welding stages: In some projects, it is worth considering the automation of final processes, such as the handling of the finished product, which significantly speeds up packaging. See more information in robotisation of packaging.
• Distribution of SIASUN robots: We are an official distributor of the brand's robots, so our customers receive comprehensive support in their implementations - from robot selection to configuration and training.
• Integration with other systems: Increasingly, machines are being designed to work in smart factories, where data from sensors and robots is collected in MES/ERP systems and analysed in real time.

Key standards and regulations (safety and ergonomics)

In the design process, the standards and regulations that govern must not be forgotten:

• Occupational safety (Machinery Directive 2006/42/EC).
• Ergonomics of workstations (e.g. requirements for height of worktops, placement of controls).
• Electrical and mechanical installations.
• Security systems to prevent unauthorised operator interference (e.g. light curtains, security locks on doors).

Legal compliance of the design is the key to avoiding sanctions and ensuring maximum protection for workers. Therefore, a reliable designer always takes these issues into account at the initial concept stage.

Machine design in practice - expert advice

Many years of practice have shown that there are a number of universal tips to help avoid mistakes and achieve the desired goals:

• Set precise assumptions: Most misunderstandings arise from a lack of precise arrangements or chaotic changes during the work. Write down requirements in the form of a brief or technical requirements document.
• Include simple maintenance methods: Even state-of-the-art equipment will need servicing. Ensure easy access to key components.
• Maintain configuration flexibility: If the company plans to develop the line in the future, consider the possibility of extending or replacing certain modules as early as the design stage.
• Ensure useful and readable documentation: A complete package of drawings and instructions (including health and safety) is one of the cornerstones of efficient operation and servicing.
• Use the services of proven specialists: Working with an experienced engineering team saves time, avoids mistakes and provides a comprehensive view of production needs.

Examples of applications in various industries

Industrial machine design can be found in many sectors. Below are some examples of applications:

• Food industry: Food packaging lines, ingredient dispensing stations. A high degree of hygiene and protection from contamination is usually required here.
• Metal industry: CNC machining stations, welding robotisation (we also have offer of welding robotisation), handling heavy components.
• Automotive: Specialised assembly lines with multiple robotic points, including coating, painting or welding.
• Wood and furniture industry: Transport systems, woodworking machines, painting lines.

Each industry brings its own challenges regarding the machine's operating conditions, precision or safety requirements. A properly designed machine should always take into account the specifics of the production process.

Summary of top tips

Below, in list form, are the key findings:

1. Thorough needs analysis: Take the time to define precise requirements, budget and performance expectations.
2. Robust 3D design: Take care of detailed CAD models and verify them with your team and external experts before you start producing components.
3. Conduct simulations and tests: Endurance and commissioning test analyses reduce the risk of future failures.
4. Good technical documentation: 2D drawings, control diagrams, health and safety instructions - it all needs to be consistent and legible.
5. Thinking about future expansion: Even if the project does not involve an increase in capacity at the outset, it is worth leaving room for possible expansion of the site.
6. Invest in automation and robotisation: The design of industrial machinery can incorporate robotic implementations to improve and modernise production.
7. Choose experienced suppliers: By entering into a partnership with a trusted company, you save time, money and are assured that every stage of the project will be fully worked out.

With these practical tips, you can significantly increase the chances of your project's success and avoid many common problems (e.g. budget overruns or unplanned downtime).

Completion

Designing industrial machinery is a process that requires knowledge, experience and attention to detail. It involves an analysis of needs, the preparation of concepts and documentation, and then the precise construction, control and possible robotisation. At each stage, dialogue between the designers and the client is paramount. A proper understanding of the company's objectives and requirements allows the design of a machine that will ensure increased productivity, safety and quality.

At Michale Automation, we have experience in the design of machines and production lines, industrial automation and the implementation of robotic workstations. If you want to improve your company's production processes, please visit Michale services and contact us for a free consultation. We will be happy to help you choose the most efficient solutions - machine building is our speciality, and we are supported in this by state-of-the-art SIASUN automation and robots, of which we are an official distributor.

We also invite you to take a look at our offer robotisation of packagingwhich can be the next step in optimising your production lines. Together, we will ensure that the final result meets all your needs and provides tangible benefits in the long term.

We hope that this article will help you understand the basics of industrial machine design, inspire you to innovate and provide you with knowledge that will translate into real improvements in your production facility. If you have additional questions, are looking for further advice or would like to gain a customised solution - get in touch and get in touch with modern technology today!

FAQ

How long does it take to implement automation in a company?
The implementation time depends on the complexity of the processes and available resources. It can range from a few weeks for simple solutions to several months for extensive projects and large integrations.

Does automation mean redundancies?
Usually no. Automation allows employees to focus on more creative and strategic tasks, while freeing them from monotonous tasks. Many companies use this to retrain and develop their team professionally.

Does robotisation only pay off for large companies?
Today, advances in technology are leading more and more small and medium-sized companies to turn to robotisation. Costs are coming down and flexible solutions can deliver a favourable return on investment even for smaller operations.