We provide our cusotmers to achieve their lean manufacturing targets.
Lean manufacturing is a methodology proven to drive outstanding business performance by improving processes and enhancing customer value through systematically eliminating loss of time and money.
By adopting a lean approach thro' Industrial automation you will have the potential to:
Wheels are delivered to the palletizing cell at a fixed location per the layout drawing via two lanes of customer supplied conveyors. Wheels are supplied to the palletizing cell at 1000 pieces per hour per lane.
The heart of the control system includes a ControLogix PLC system communicating via Ethernet to PowerFlex conveyor drives and three (3) RSView operator interface units. On the line are 3 RSView operator interface units.
If the robot picks the tray and two or more trays are picked without successful separation, the photo eye located on the robot end effecter will send a signal so the Thumper is activated.
After the robot picks the last tray on a base, a photo eye will detect that the base is empty and will initiate the transfer mechanism that will allow for the empty base to be conveyed over to the main base conveyor.
Provisions will be made for the insertion of partial pallets of product.
When a product changeover is initiated, a changeover wheel is inserted onto the conveyor to allow the conveying system to know that the next wheel is part of a new product.
The customer desired to install systems that would provide 100% label inspection on two of their shampoo bottle lines.
Some of the major requirements for these systems were conform to FDA standards for 100% label inspection and verification to be "stand alone". provide 100% electronic inspection of bottles fit into a section of the existing conveyor approximately 12” long must operate with line speeds up to 200 fpm and product speeds up to 400 PPM have self check diagnostics must interface to the existing line’s controller to signal status of every inspection as well as to shut down the line and indicate the specific failure on a system error detect.
The system used an Allen-Bradley PLC for control, Allen-Bradley Bar Code Scanners and decoders for reading labels, Allen-Bradley photo eyes for product detection and a Filtec Pro Line reject mechanism.
The ferrule is discharged from the bowl in a vertical orientation. Because the ferrule has two different vertical orientations, only approximately half of the discharged ferrules are correctly orientated. The bowl feeder is unable to differentiate between the internal barbs being upright or downward. A sensor is used to look inside the ferrule and detect the location of the internal barbs. If the barbs are down, the ferrule will proceed. If the barbs are up, the ferrule is placed back into the bowl. The ferrule is gripped, lifted and horizontally transferred to the turntable.
The nut is discharged from the bowl feeder/vibratory inline with the flare side facing down. The nut is gripped by the hexagon perimeter and placed over the flared end of the insert body. A pilot guide on the gripper is used to accurately locate the insert body before placing the nut.
The insert body is discharged from the bowl feeder/vibratory inline with the stem facing down. The nut is placed on the stem at an escapement on the inline. The assembly is transferred to the dead nest. The insert body and nut is gripped by the hexagon perimeter and placed inside of the ferrule on the turntable.
Pouches that pass inspection are conveyed to the second section of the machine. This section of the machine requires seven (7) stations to fold the foiled pouch and crimp the flaps. After successful completion of the folding operation the pouch is conveyed by a servo conveyor to a rotary pick and place. Pouches not folded properly are pneumatically rejected.
The 180-degree servo driven rotary pick and place uses pneumatics to raise/lower the pneumatic grippers, which grasp the pouch. After the pouch has been grasped from the folding section, the pick and place rotates and moves the pouch to the packaging section of the machine.
The packaging section consists of a servo conveyor and pneumatic tray and lid dispensers. Twelve (12) pouches of the folding section are placed into a tray. Once the tray is full of pouches, the tray is indexed to the lid section where the lid is automatically applied.
Up to 40 pouches per minute are inspected, folded and packaged. The aluminum foil pouch is approximately 4” wide x 8” long. All equipment was made out of anodized aluminum or stainless steel to meet the clean room environment.
The customer provided some of the programming for the folder section, which i-Matics converted, from Siemens to Allen-Bradley. i-Matics did all other required programming.
i-Matics wrote a functional specification to provide a "roadmap" for the project. This included concepts, database design, system screen and reports.
Programmed the PLC's to properly handshake with the recipe system. Also set up auto additions to occur when the recipe system initiated them.
i-Matics implemented a data-gathering scheme to collect process information pertinent to all recipes running in the system. This information was placed on a RAM disk, and all other nodes could access it. Reports are generated automatically and upon demand.