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KEYENCE Advantage Machine Design


Tilt Correction

Problem:
The laser marker cannot be mounted perpendicular to the product.

  • Generic Laser System

    1. STEP 1
      Calculate angle difference.
    2. STEP 2
      Design/purchase mechanism to adjust for the angle.
    3. STEP 3
      Runoff to ensure +/- 2 mm tolerances are held.

    Hardware Additional Cost

    $5,000 to $50,000 Additional cost of hardware (robot/fixturing).

    Labor

    2 to 10 days Additional time for design, runoff, and future maintenance.
    $1,000 to $5,000 In engineering costs.

  • KEYENCE ADVANTAGE

    Use tile correction to allow marking on surfaces not perpendicular to the laser.

    Hardware

    None

    Labor

    15 minutes for extra programming.


Z-Height Adjustment

Problem:
Marking parts that change in thickness or height.

  • Generic Laser System

    1. STEP 1
      Create table of various part heights.
    2. STEP 2
      Design and build a nest for each type of part.
    3. STEP 3
      Design and build fixture to hold each nest.
    4. STEP 4
      Runoff to insure +/- 2 mm tolerances are held with each nest.

    Hardware Additional Cost

    $1,000+ Cost to produce each nest. Multiple nests may be needed for different height parts.

    Labor

    1 to 2 days Labor time varies depending on the complexity and number of nests needed.
    $600 to $1,200 In engineering costs.

  • KEYENCE ADVANTAGE

    Automatically adjust for height by switching between the 2,000 available programs.

    Hardware

    None

    Labor

    15 minutes extra programming per part height change.


Autofocus

Problem:
Marking on a target that is constantly changing height.

  • Generic Laser System

    1. STEP 1
      Design a system to measure distance from laser to part in real time.
    2. STEP 2
      Design or purchase system to adjust distance in real time.
    3. STEP 3
      Runoff to verify good marks within necessary marking time for production.

    Hardware Additional Cost

    $10,000 to $30,000 Cost of measurement system and mechanical device to move the part/laser head.

    Labor

    5 to10 days Programming a system to make the necessary adjustments + annual maintenance.
    $5,000 Approximate cost of labor.

  • KEYENCE ADVANTAGE

    Use built in autofocus to adjust to part changes on the fly.

    Hardware

    None

    Labor

    None - simply select from menu.


Wide Area

Problem:
A product needs to be marked in two places and separated by 10 inches in the X and 1 inch in the Z.

  • Generic Laser System

    1. STEP 1
      Purchase two laser markers to cover area and height change.
    2. STEP 2
      Design or purchase system to mark parts and divide work load between units.

    Hardware Additional Cost

    $40,000 to $60,000 Cost of additional laser marker depending on the application. Additional marking station will cost between $10,000 -$30,000.

    Labor

    Initial programming and maintenance of two lasers will cost more up front and over time.

  • KEYENCE ADVANTAGE

    Can mark up to 13" × 13"

    Use our Wide area marker.
    *MD-X1000/X1500 Series 330 mm × 330 mm

    Hardware

    $5,000 Additional hardware cost over the standard area laser.

    Labor

    None


3D Pallet Marking

Problem:
Production cannot be increased because marking on complex shapes requires time-consuming part indexing.

  • Generic Laser System

    1. STEP 1
      Design or purchase a system to load and rotate each part.

    Hardware Additional Cost

    $10,000 to $50,000 depending on the shape of the part and accuracy needed.

    Labor

    Automatic systems will require maintenance, replacement and additional programming for future parts. Manual systems will require the cost of operators and suffer from losses in productivity and throughput.

  • KEYENCE ADVANTAGE

    Mark all parts in the nest at one time.

    All parts in the nest can be marked at one time. 3D software and pallet marking function can adapt to each part in the pallet.

    Hardware

    None

    Labor

    None


3D Programming

Problem:
Laser marking complex shapes in multiple locations is not possible.

  • Generic Laser System

    1. STEP 1
      Design a robot system to hold the part.
    2. STEP 2
      Program the robot to rotate and position the part for the different markings.

    Hardware Additional Cost

    $10,000 to $50,000 to purchase a robot to adjust for shape depending on size of the part and scope of the project.

    Labor

    Will require a technician to program the robot to make any adjustments needed over time. The cycle time will be much longer than the KEYENCE option.

  • KEYENCE ADVANTAGE

    Easily import CAD data of product

    Use Z-map to import the 3D model of the part.
    *Not available for ML-Z9500 Series

    Hardware

    $2,000 for additional software.

    Labor

    Minimal time to import geometry of parts into Marking Builder.

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