Task:
The desire for high flexibility and increased productivity required us to develop a fully automatic system for the assembly of decorative and trim rings (see semi-automatic solution).
In addition to a cost-effective solution, the main focus was on high availability and resilience.
Solution:
When designing the system, Klotz was able to draw on 20 years of experience in the field of ring assembly. At the same time, Klotz has a great deal of experience in the assembly and handling of highly sensitive surfaces, such as enameled objects. These insights and the knowledge of the changes in the market (e.g. small batch sizes, high quality, optimum delivery readiness of the operator) were the cornerstones of the new development.
The main focus was placed on the simple operation of the machine and a high degree of automation of the operating process. However, this alone is not enough to meet customer requirements today.
The system has therefore been designed so that up to six pot and lid sizes (6 diameters) can be produced without any conversion work, with five options available:
- Diameter-related gripper devices must be replaced during feeding.
- The roller must be positioned to the respective diameter.
- All positions are equipped with position sensors.
- The respective position can be selected using a selector switch.
- A scanning system recognizes the size of the pot and the system automatically adjusts to the respective pot. Production can therefore be chaotic.
- The system can be equipped with a handle assembly for lids.
- When the part is removed, it is placed in the box provided, which is then transported away.
The entire machine is equipped with state-of-the-art drive and control systems.
All valves are equipped with signal lamps for fault analysis.
If desired, the exhaust air can be recorded centrally.
The machine can be operated directly in front of the respective station during set-up operation. The control panels required for this are attached to the work station. They are deactivated when the safety guard is closed.
The feeding device is equipped with an adapted half-shell, which takes the part from the conveyor belt with the manually placed ring and feeds it to the rotary table.
The alternatives assume that the tool automatically adapts to the sizes.
Technological process
The enameled part (pot or lid) comes off the oven chain, is removed by hand and checked. The ring is then placed on the part manually. In this state, the parts are placed on the conveyor belt, which is equipped as an accumulation belt so that a certain number of pieces can be presented.
The separation of the transfer is already fully automatic.
The parts are moved by means of a drag plate to roll up or press off the ring. The drag plate has three idle stations, which can be used for button assembly if required.
The assembled part is removed by a gripper that places the workpiece on a conveyor belt. As an option, the parts can be placed in a cardboard box.
When the protective grille is closed, only automatic operation is possible.
After an emergency stop, each individual station can be returned to its initial position at the touch of a button on the control panel on the cabinet.
