Fully Automatic Ring Assembly Machine
Task:
Fitting of ornamental and facing rings must be fully automatic since the systems developed so far have not optimally met the demands placed on our customers by the market.
The call for greater flexibility and increased productivity required from us a new development concept. In addition to an inexpensive solution, the necessity for high availability and loading capacity were the main requirements.
Solution:
When designing this system, we could fall back on 20 years of experience in the field of ring fitting, particularly for highly sensitive product such as enamel.
This knowledge, an awareness of the changes in the market structure (e.g. small runs, high quality, optimum delivery readiness of the operator) were the aims of the new development.
With this product we have developed an automation module that is proving its worth in production. The entire facility has been modified in a manner that points the way ahead for the future.
The main factor considered was simple operation of the machine and a high degree of automation of the operating process. This however is not sufficient on its own to comply with the parameters set by the customer.
For this reason, the facility was designed so that up to six pot and lid sizes – i.e. diameters – can be produced, with five options available
- In the feed system, diameter-based gripper units must be changed, and the roller positioned to the appropriate diameter.
- All positions are provided with position pickups. The appropriate position can be selected using a selector switch.
- A scanning system recognises the size of the pot and the facility automatically adjusts to the pot. It is thus possible to produce all sorts of pots.
- The facility can be equipped for lids with a grip fitting feature.
- The part is removed and then placed in the carton provided, which is then conveyed away. The entire machine is fitted with the latest drive and control systems. All valves are fitted with signal lights for fault analysis. If required, the waste air can be handled centrally.
The machine can be operated from directly in front of the appropriate station in setup mode. The necessary control consoles are provided at the workplaces. When the safety grille is closed the consoles become inoperative.
As previously mentioned, the feed unit is provided with an adjusted half-dish that takes the part with its manually fitted rings from the conveyor belt and supplies it to the rotary table. The alternatives assume that the tool automatically adjusts to the sizes.
Technological Sequence
The enamelled part (pot or lid) arrives from the furnace chain, is removed manually, and checked.
The ring is then placed manually onto the part. The parts are placed in this condition onto the conveyor belt, which is of the backup type so that certain quantity can be positioned.
The separation of the transfer unit is already fully automatic. For rolling up or pressing on the rings, the parts are introduced by a pulling plate. This pulling plate has three no-load stations which can be used if required for knob fitting.
The fitted part is removed by a gripper that deposits the workpiece on a conveyor belt. There is an optional possibility of placing the parts in a carton.
When the safety grille is closed only automatic operation is possible.
After Emergency Off, each station can be moved to the starting position at the push of a button using the control panel on the switch-gear cabinet.
Specifications
Cycle time: 6 to 7.5 sec
Width: 3.7 m
Length: 5.0 m
Height: 2.2 m
Weight: 2800 kg
Pneumatic connection: 6 bars, 1/2″
Connection load: 380 V, 25 A
Control voltage: 24 V
Workpiece dimensions
Min. diameter: 90 mm
Min. diameter: 300 mm
(other dimensions on request)
Control: Siemens S5-115U electric/electronic freely programmable and pneumatic-hydraulic
Electrical sequence: Single functions
Semi-automatic (automatic run of a station)
Fully automatic
