Engineering · Design for Manufacturing · 7 of 8
DFM for Industrial Automation Machines
How much of this machine could be ordered from a catalogue, and how fast could one station be swapped out?
An automation machine is mostly bought parts held together by a frame, cables and air lines. DFM here means choosing catalogue components first, splitting the machine into modular stations, keeping plates and brackets to standard sizes, and planning cables, pneumatics and service access while the layout is still a sketch. Four small tools help: plate stock size, cable bend radius, cylinder air use and levelling-foot load.
1Use catalogue parts: standard components
On an automation machine most of the bill of materials should be bought, not made. Pick a category to see why and what to watch.
2Modular machine layout
| Element | DFM point |
|---|---|
| Modular stations | Easy to add or remove; split the machine into independent stations. |
| Standard aluminium frame with gussets | Common frame and interface standards. |
| Adjustable sensor brackets | Setting without re-machining. |
| Pneumatic gripper and robot | Standard, catalogue units. |
| HMI and control panel | Modular electrical cabinet with quick connectors. |
| Safety fencing with access doors | Standard guard panels; plan access early. |
| Conveyor and cable carrier | Standard items with proper cable routing. |
| Levelling feet with anchor option | Level the machine without shims. |
Split the machine into independent stations, use a common frame and interface standard, and give each module quick mechanical and electrical connectors. That cuts design, manufacturing and maintenance time and makes the machine easy to reconfigure.
3Fabricated frames
Do
- Use standard structural sections (RHS, SHS).
- Minimise unique profiles.
- Keep welds simple and accessible.
- Add gussets and stiffeners at high-load points.
- Design for easy fixturing and welding.
- Allow levelling and anchoring.
- Provide machining allowance on critical mounting surfaces.
- Add mounting pads for future options.
Avoid
- Many different section sizes.
- Welds that cannot be reached.
- Critical mounting faces as-welded with no stock to machine.
4Machined plates and brackets
Standard plate thickness and mass
Common stock thicknesses are shown; confirm what your supplier holds. Density in g/cm³.
Do
- Use standard plate thicknesses (for example 6, 8, 10, 12 mm).
- Use common hole sizes and tool-friendly features.
- Design for easy clamping and 3-axis machining.
- Use radii instead of sharp corners, and standard dowel holes for location.
- Combine features to cut part count.
Avoid
- Odd thicknesses that need a full plate from a mill.
- Features on several faces.
5Sensor mounts and adjustability
Slotted holes for adjustment
So a sensor can be set without machining.
Standard sensor brackets
One bracket family across the machine.
Rigidity
Brackets stiff enough to avoid vibration in the reading.
Easy access
For cleaning, setting and replacement.
6Cable routing and electrical layout
Cable bend radius
Multiples are typical for flexible cables; the cable maker’s data sheet is the real limit, and moving cables in a carrier must use the carrier’s bend radius.
Do
- Use cable carriers for moving axes.
- Separate power, signal and pneumatic lines.
- Keep proper bend radius and strain relief.
- Provide service loops at moving joints.
- Route through frame channels or cable trays.
- Label both ends of every cable.
- Keep cables away from heat and chips.
- Plan cable entry to the electrical cabinet.
Avoid
- Sharp edges and pinch points.
- Power and signal cables bundled together.
7Pneumatic layout and design
Cylinder air consumption
free air = volume × (p + 1.013) / 1.013 × cycles
Free air is air at atmospheric pressure. The figure ignores pipe volume and leaks, so size the compressor and supply line with a margin.
Do
- Use a standard filter-regulator-lubricator (FRL) unit.
- Group valves in manifolds and use manifolds to reduce plumbing.
- Keep tubing short and neat, with push-in fittings.
- Provide flow control for speed and quick exhaust where needed.
- Allow space for additional circuits; colour-code circuits.
Avoid
- Long tubing runs between valve and cylinder.
- Many separate valves with separate tubing.
8Cost-reduction ideas
Use standard parts
Avoid custom versions of catalogue items.
Combine functions
Reduce part count.
Use regular machining
3-axis, avoid 5-axis unless needed.
Common materials
Aluminium, mild steel in standard grades.
Design for easy assembly
Minimise fasteners.
Optimise for manufacturability
Uniform thickness, standard holes.
9Levelling feet and machine mass
Foot load check
On an uneven floor one foot can carry little load. For four feet with the centre of gravity in the middle and one foot off the floor, the two neighbours each carry half the weight. For other counts use at least twice the even share. Add the load from any covers, product and external forces.
10Serviceability and maintenance
Easy access to key components
Motors, valves and sensors reachable without dismantling.
Removable panels
Quick-release covers.
Clear labelling
Cables, pipes and components.
Standard components
Easy replacement and spares.
Provide manual override
Valves and actuators.
Allow space for tools
Room to use the tool.
11Try it: DFM checklist for automation machines
Automation DFM scorecard
Remember
- Buy it if it is in a catalogue; make only what must be custom.
- Split the machine into modular stations with common interfaces.
- Plan cables, air and access while the layout is still a sketch.
- Design the machine so a technician can service it with ordinary tools.
- Boothroyd, Dewhurst and Knight, Product Design for Manufacture and Assembly (CRC Press), for the DFM and DFA method.
- Machinery’s Handbook (Industrial Press), for machining, sheet metal and welding practice.
- Cylinder air consumption: standard free-air formula using the absolute pressure ratio.
- Cable and carrier makers’ data sheets for bend radius.
Plate sizes, bend-radius multiples and foot-load rules are typical planning values. Use the supplier data sheet and your own load case for the final design.