A step-by-step approach to machine design: a practical guide

Estimated reading time: 12 minutes

TL;DR

• Precise define business objectives and technical requirementsto avoid costly repairs
• Use 3D modelling and simulations for early project verification
• Prototype and test under realistic conditions in order to identify potential errors
• Take care of safety and compliance with standardsincluding the Machinery Directive (2006/42/EC)
• Consider automation and robotisation to improve efficiency
• Make a plan after-sales support and modernisationto extend the life of machinery

Table of contents

• Introduction
• Definition of project objectives and requirements
• Concept development and technology selection
• Prototyping and testing
• Integration with automation and robotics solutions
• Validation, certification and preparation for implementation
• After-sales support and project development over time
• When to opt for an external partner in machine design?
• Examples of machine design and potential challenges
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

Machine design is now not just a matter of creating equipment that meets the required parameters, but above all a process designed to enable companies to produce efficiently, safely and flexibly. In an era of dynamic market changes and shortages of staff and know-how, properly designed machines allow businesses to scale operations, streamline processes and reduce production costs. That is why, in this article, we will focus on the 'how' - on the practicalities of the machine design process, in order to plan, step-by-step, the steps needed for success.

From the perspective of Michale Automatika, which specialises in machine and line construction and industrial automation, the design process is crucial to fully exploit the potential of new technologies and help companies optimise their production. After reading the article, you will learn how to define the technological requirements, which tools to use for 3D modelling and how to test prototypes so that your project combines innovation and safety.

Definition of project objectives and requirements

The first important step when designing machinery is to precisely define the business objectives, technical parameters and legal requirements that the target solution must meet. A good understanding of the production context, the potential working environment and the needs of employees (or operators) is the foundation on which further design work is based.

Analysis of the production environment

Before you start any drawings or modelling, do a thorough review of the environment in which the machine will operate. Consider:

• What type of production processes are already in place in the environment?
• Are there production lines in the company that need to be integrated with each other?
• What are the specifics of the product or intermediates (weight, size, possible future changes)?

This will help you determine whether it is worth investing in full automation or whether you need a semi-automated machine that takes into account more operator input.

Technical and safety requirements

The machine must meet a number of requirements including operator safety and production quality. In practice, this means:

• Risk assessment - identifying what hazards are present during the operating stage of the equipment (for example moving parts, high temperatures, chemicals).
• Selection of appropriate guards, alarm systems, safety buttons (so-called 'mushrooms'), as well as ergonomic elements.
• Ensuring compliance with standards and directives, e.g. the Machinery Directive or ISO standards for machine safety.

Budget and expected added value

Remember that any investment, including machine design, should have a well-founded budget. It is worth considering, among other things:

• Costs of developing concepts and prototypes (e.g. engineering services, software).
• Potential costs of series production (if you plan to deploy the machine in multiple sites).
• ROI perspective and added value - will your machine reduce labour costs by a significant percentage or reduce quality defects?

Concept development and technology selection

Once the objectives and requirements have been established, it is time to move on to the conceptual phase. A properly prepared project cannot do without well-chosen technology, designed to fit perfectly into the production environment.

Brainstorming and functional sketches

Before moving on to advanced computer tools, it is useful to brainstorm ideas and needs from engineers and specialists from different departments (production, maintenance, logistics). Simple sketches are often created at this stage, showing:

• Key components - where the motor, conveyor, control system will be located.
• Possible transmission methods (e.g. worm, belt, chain gearboxes).
• Orientation and dimensions of the unit in the assumed working area.

3D modelling and simulation

After the initial sketches, it is a good idea to use CAD tools such as SOLIDWORKS or Autodesk Inventor. Creating a virtual model allows you to verify the correctness of the dimensions and catch construction errors at an early stage.

• Load simulations: Strength testing of applied force, torque, temperature.
• Kinematic analysis: Especially with more complex dynamic machines - important to make sure that no components interfere.
• Integration with vision systems or IoT sensors: If advanced automated solutions are planned, it is worth examining how they will interact in a single structure.

Choice of materials and production technology

Appropriate choice of materials:

• Metals (e.g. stainless steel, aluminium) - important for machines working in contact with chemicals or foodstuffs.
• Plastics (e.g. POM, PTFE) - used in components requiring low friction or better corrosion resistance.
• Composites - especially in machinery where lightness and fatigue resistance are important.

At this stage, it is already worth planning the production process in terms of the machinery available. Will you be milling parts, turning them, 3D printing them? The answer to this question is related to the level of accuracy, durability and final costs.

Prototyping and testing

Once you have got past the concept phase, there comes a point when it is worth building an initial prototype. Even the most accurate 3D models are no substitute for practical verification of the machine's operation.

Construction of the first units

More often than not, a prototype is built from cheaper substitute materials to test key functions or explore ergonomics. Only when the prototype works properly are the target, often more expensive solutions (e.g. specialised metal alloys) implemented.

• Checking the dimensions and fit of the components.
• Verification of ease of use: whether the operator can easily change tools, whether the feeders operate smoothly.
• Safety tests: checking emergency shutdowns and safety barriers.

Performance and reliability tests

During testing, you check under which conditions the machine behaves correctly and whether unforeseen faults arise. Don't rush into a final evaluation of the prototype - a reliable test session can take days or even weeks.

• Working under varying conditions (temperature, load, dust).
• Full duty cycles, as close as possible to the target environment (e.g. series production).
• Sensor data collection: measurement of vibrations, pressure, energy consumption, etc.

Optimisation and correction

When you notice that certain solutions do not meet expectations, do not hesitate to adapt the prototype. Sometimes these are minor adjustments to the existing design (e.g. strengthening the bearings), and sometimes you implement more serious changes, such as a plan to rebuild an entire conveyor section.

It is good practice for project teams, operators and maintenance people to work together on an ongoing basis. Collaborative data analysis and suggestions can catch potential sources of failure faster, resulting in a final product.

Integration with automation and robotics solutions

Many machines become even more efficient when integrated with modern industrial automation systems or robots, including collaborative robots (so-called cobots). At Michale Automation, we provide complete solutions for building our own machines and integrating them with control systems. Robots from various global manufacturers also perform well in selected situations - Michale Automatika cooperates with SIASUN, among others, of which we are an official distributor.

Main advantages of automation

• Precision: Eliminating human error in assembly, packaging or welding processes.
• Speed: Ability to work 24/7 without downtime or fluctuations in performance.
• Optimisation of human resources: People can focus on more creative tasks.

Operator interface design and control schedules

To keep the machine running reliably, it is worthwhile to ensure that the operator interface is clear and easy to use:

• Starting and stopping the work sequence.
• Monitoring of key parameters (e.g. vibration level, current speed).
• Reporting defects and requesting service work.

A well-designed control system, including PLCs, HMIs and sensors, will minimise downtime and make it easier to regulate production parameters.

Validation, certification and preparation for implementation

Before your machine hits the production floor, it should pass the validation stage, during which compliance with all standards and legal requirements is checked. Half-measures will take revenge in the future - better to eliminate non-compliance at this stage than face penalties or problems during use.

Technical documentation and evaluation of conformity

EU and local regulations require full documentation: from technical drawings to operating and maintenance instructions to Declarations of Conformity. For machinery in the EU, the key points are:

• Machinery Directive (2006/42/EC).
• Safety standards (e.g. EN ISO 12100).
• CE certification if the product is to be marketed in the European Union.

Preparation of operators and staff

A machine designed even perfectly from the construction side will not work efficiently if people are not properly trained in its use. This applies not only to the operators, but also to the maintenance staff who will be responsible for maintenance and repairs.

• Health, safety and machine safety training.
• Hands-on instruction in daily maintenance and replacement of consumable components.
• Implement a rapid emergency response system.

After-sales support and project development over time

The investment in a new machine does not end with technical acceptance and commissioning. Regular maintenance and service are needed to keep the equipment running optimally, as well as a project development plan that takes into account future changes in the market.

Periodic inspection and maintenance

Systematic maintenance is key to maintaining reliability. At Michale Automatika we place great emphasis on this, as even the slightest fault can stop a production line for hours. If you are interested in service support, check out our offer:

• Service and station maintenance - Michale Automation offer

A well-planned maintenance schedule (quarterly check, half-year check) can quickly detect wear and tear on key components before a major breakdown occurs.

Scaling and upgrading

In today's ever-changing market of technology and customer requirements, it is worth thinking in advance about possible machine upgrades. This could mean adding robots to an existing line, extending control systems or implementing new sensor technology.

• Introducing energy-saving modes.
• Increasing the scope of operations (e.g. adaptation to new product types).
• Integration with MES/ERP class software.

When to opt for an external partner in machine design?

Not every company has an extensive R&D (Research and Development) department or the competence to carry out complex machine design in-house. In this case, it is worth considering working with an external partner that has a team of specialists and extensive practical experience.

Industry experience and technological support

At Michale Automatics, we design machines from the ground up, taking into account the expectations of customers from various industries. By working with us, you gain:

• Access to specialists in automation, robotics, mechanics and electronics.
• Ability to implement proven solutions quickly.
• The option to integrate with SIASUN robots, of which we are an official distributor, if such an implementation proves justified.

Comprehensive turnkey service

An external partner can offer you a turnkey service - from needs analysis and design to installation and staff training. Here, the flexibility to adapt to specific market requirements and internal company standards is also important. If you are wondering whether robotisation solutions could enhance the machine you are designing, take a look at our automation services department:

• Robotics - a wide range of services at Michale Automation

Examples of machine design and potential challenges

Below you will find some examples of areas where machine design works particularly well. In each case, the key is to precisely define your needs and use the right technologies.

Packaging machines in the food industry

In the food industry, hygiene and speed are important. When designing a packaging machine, corrosion-resistant and often easy-to-clean materials (e.g. stainless steel) must be selected. Integration with pick-and-place robots can be useful when customised packages need to be handled quickly.

Automotive assembly lines

Complex assembly processes require the synchronisation of several stages at once. When designing such a machine, consideration must be given to transport pipelines, robots performing minor assembly operations, and vision systems for quality control.

Machining machines

Milling machines, lathes or machining centres - their design requires a high degree of expertise in precision mechanics, tool cooling and minimising vibration during operation. A stable base structure and perfect axis alignment also count here. If your company is considering the automation of grinding processes, check out the sample offerings in this area:

• Robotisation of grinding - possible applications

Practical conclusions and recommendations

• Plan ahead: Clearly define business objectives and technical requirements to avoid costly design amendments.
• Use 3D tools and simulations: They make it possible to reduce the number of mistakes and verify project assumptions at an early stage.
• Invest in prototypes and tests: Real-life use of the device catches all the shortcomings - often ones that cannot be foreseen in the drawing.
• Ensure safety: Machines must comply with standards and be equipped with appropriate protection systems.
• Consider automation and/or robotisation: Integrating the machine with robots or control systems can increase productivity and production quality.
• Remember about after-sales support: Regular servicing and maintenance definitely extends the life of the unit.

Summary

Machine design is not just about engineering drawings and calculations - it is a process in which understanding customer needs, production realities and safety requirements is key. It starts with analysis and definition of objectives and ends with validation and certification of the finished product. At each stage, it is useful to work with teams and specialists who can take a critical look at the concept and suggest improvements in terms of mechanics, automation or robotics.

If you are wondering how to improve your company's machine design or need comprehensive support in developing a new production line, we encourage you to visit our website and check out the details in the services section:

• Services - design and construction of machinery in Michale Automation

There you will find more information about bespoke solutions that help companies achieve higher productivity and safety. We also invite you to contact our team so that you can make the most of modern technology and the experience of specialists in the industrial automation sector.

Thank you for reading and feel free to share your machine design experiences in the comments or by contacting us directly. We hope this guide will help you to organise your machine design process from the ground up - from setting goals to implementing and servicing the finished solution. Use it to successfully compete in the demanding industrial market and systematically modernise your production processes.

FAQ

How long does it take to design a machine?
Design time depends on the scale and complexity of the project. Simple machines can be designed in a few weeks, with more advanced machines it can take several months.

Does the machine have to be CE marked?
Yes, if it is to be sold or used in the European Union and falls under the Machinery Directive. The CE marking confirms that the machine complies with health and safety requirements.

What are the costs of prototyping?
The cost of a prototype depends mainly on the type of materials used and the complexity of the device. Cheaper substitutes are often used to reduce expenses during the initial functional testing phase.

Can an existing machine be integrated with a robot?
Many older machines can be upgraded and robotised, but this requires technical analysis and adjustment on both the mechanical and control side. Working with an experienced integrator increases the chances of success for such an upgrade.