The Mechatronic Application Includes:

 PICK AND PLACE

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Pick-and-place applications comprise both primary handling—putting individual pieces of product into a tray or carton—and case packing. Advances in materials of construction, controlling software and hardware, vision systems and other aspects have made robots, of various types, an increasingly viable option for pick-and-place. 
The type of robot most appropriate for a given pick-and-place application depends on the speed required, the size of the payload and other factors. For most applications, only one type of robot will be appropriate. But there are many borderline applications where more than one type could be used, and the end user (or his/her system integrator) must prioritize the factors. 

Another development is refinements to motion control software and hardware. Motion control is the essence of robotics. It’s needed to find objects, to guide the robot arm in picking them up and releasing them, and to coordinate with equipment upstream and down. 

In the past, operating a robot would have required integration between the robot’s motion controller and the programmable logic controllers (PLCs) that coordinate the robot’s actions with the rest of the line. But the trend has been to combine those functions, as much as possible, into common controllers. This eliminates software coding that would otherwise have been required to coordinate the separate controllers. 

Several kinds of robots can be used for upstream pick-and-place: 

• Delta-style robots that operate from overhead with three or four long, thin arms that meet at the effector head; 

• SCARA (selective compliant articulated robot arm) models, which are fixed-base robots with three vertical-axis (horizontal-motion) rotary arms; and 

• Multi-axis articulated robots, which can have up to six axes, with joints that can rotate in any direction. 

As with most aspects of packaging, end users want pick-and-place to run as fast as possible. But some applications have practical limitations. Fragile products like baked goods have to be handled gently, which means slowing down. 

Pick-and-place applications are fertile ground for robotic equipment. As technology and other developments make such equipment increasingly viable, end users who pick the right machines will find themselves in a good place. 

GAUGING

 GAUGING

SHIM SELECTION /  FORCLIP

5point

 Automated Shim Selection Machine

“We have developed a new test based system using MicroLogix 1400 PLC (Allen Bradley) & Panel View Component 400 HMI (Allen Bradley) hardware & RSLogix 5000 software. System is highly rugged, flexible & cost effective, Increasing productivity of assembly line by 20X & we guarantee measurement accuracy within ± 10 microns”.

Challenge

To develop a test system for accurate measurement of Shim (Gasket) size required to avoid leakage of pressure between Crankcase face & cylinder of compressor. That has been achieved very well by our existing PLC based system.

Solution

Developed a highly rugged, flexible & cost effective, increasing productivity of assembly line by 20X & we guarantee measurement accuracy within ± 10 microns with Allen Bradley world class Automation control system.

What is Shim?

Shims are commonly used to adjust the clearance or space between two parts. For example, shims are inserted into or under bucket tappets to control valve clearances. Clearance is adjusted by changing the thickness of the shim.

What is Gasket?

A gasket is a sealing device made of deformable material usually designed in the form of a ring or sheet. Gaskets create a pressure-tight seam between multiple stationary components, relying on a compression seal to prevent unwanted gas or liquid emissions. These seals are often intended to be resistant to pressure, temperature fluctuations, and in some cases, electrical or electromagnetic forces. Since it uses compression, a gasket is typically more malleable than the components it joins and is able to conform to the shape of the harder surfaces between which it is placed.

System Configuration

The test system, which we created for Shim (Gasket) selection consist of one fixture station for the measurement of distance between piston top & crankcase face position when piston is moving upward with respect to crankcase face. The selected shim width is equal to measured distance to avoid leakage of pressure between crankcase face & cylinder of compressor. The system contains one load sensor for Shim (Gasket) selection. One pneumatic system at fixture station brings the probe of load sensor in contact with crankcase face, piston top applies load at probe of load sensor to measure the width of required Shim (Gasket) size for particular unit. LED lamp glows for indication & pneumatic system opens to pick required Shim (Gasket) size for that particular unit .There are 22 different digital LED lamp indication & pneumatic system for each Shim (Gasket) size as per requirement.

The system uses the MicroLogix 1400(PLC) for controlling the entire process & Panel View Component 400(HMI) to monitor the status of required Shim (Gasket) size for particular unit. Load sensor calibration for precise measurement & accurate Shim (Gasket) selection with respect to master is also available in our system for convenience of user.

System Implementation

We implemented the entire system within 10 man-days. User friendly Allen Bradley software & Hardware helped us to complete system in such short time. An experienced employee takes approximately one minute to measure and select the appropriate shims manually. Error in manual measurements depends on the employee and his fatigue level & it also effect quality policy. But with our new test system, the entire measurement and Shim (Gasket) selection process takes less than three seconds.

The system has two mode of operation:-

  • Auto Mode
  • Manual Mode

In manual mode, the system carries out all mechanical actions guided by user via HMI. Operator can load Shim (Gasket) manually in all pneumatic arrangements. In auto mode, all operations are carried out automatically after the “cycle start” user acknowledgment. Shim (Gasket) sizes are measured as per load applied by piston top on probe of load sensor. The system guides the user through the message display in the HMI along with LED lamp indication & pneumatic system as per selected Shim (Gasket) size.

Our new test system based on AB hardware’s and software is highly flexible, rugged, and cost-effective, increasing assembly line productivity by 20X and guaranteeing Measurement  accuracy within ±10 microns.

SUB-ASSEMBLY COMPONENT MEASUREMENT & VERIFICATION

SUB-ASSEMBLY 1 SUB-ASSEMBLY 2 SUB-ASSEMBLY3

Measuring for dimensions for various sub-assemblies and hence identifying whether they are the correct sub-assembly part codes to go into a particular part code of main assembly. In simpler words identifying the correct dimension sub-assembly for a particular model of main assembly, for eg. Correct sub-assemblies such as main shaft, counter and drive shaft which makes the complete gear box assembly.

POKA  YOKE

POKA YOKE

PALLETIZING AND DE-PALLETIZING USING MULTIPLE AXIS  GANTRY

Palletizing products either at the end of the manufacturing  i.e final output or at an intermediate location i.e end of a line. Process can be Palletizing or de –palletizing i.e from a pallet product is needed to be put at a conveyor for a process. In simpler words PICK AND PLACE APPLICATIONS.

Example 1:

example1

Operational Sequence

  • Gantry Robot 1 will pick the part using suitable gripper and will place the part in to the shearing machine.
  • Once shearing operation is over the Gantry Robot 2 will pick the sheared part with a suitable gripper and will place the 02 parts onto the pallet 2 and the operation will continue till the pallet will be empty.
  • The last part detection will be provided on the gantry robot to generate the alarm that pallet is empty to replace it with filled pallet.
  • On pallet replacement the operator will close the safety fence and will acknowledge the automation to start the operation.

Example 2:

example2

Operational Sequence

  • Gantry Robot will pick the part using suitable gripper from pallet 2 and will place the part in to the sawing machine.
  • Once sawing operation is over the same gantry will pick the parts with a suitable gripper and will place the 02 parts onto the pallet 1 and the operation will continue till the pallet 2 is empty.
  • The last part detection will be provided on the gantry robot to generate the alarm that pallet is empty to replace it with filled pallet.
  • On pallet replacement the operator will close the safety fence and will acknowledge the automation to start the operation.

Example 3:

example3

Operation Sequence:

  • Auto Claved pallet will be placed manually on the designated location.
  • Gantry 1 will pick the part and will place onto the conveyor, where the part of the conveyor will be dedicated for the operator for the visual inspection. On inspection operator will press the ok or reject button provided on the conveyor.
  • While operator will be inspecting the gantry 1 will pick the separator and will place on the separation pallet
  • On press of the decision button the part will be transported to the unloading position on to the conveyor.
  • Gantry 2 will unload the part from conveyor and will place on to the ok or reject pallet.
  • While making this concept we have considered the separator is of type sheet (new design) and assumed no broken part will come from the autoclave on pallet.