Case Studies
Member Since 2013
Midwest Engineering Systems Inc. provides custom machines, integrated systems, automation/robotic solutions, and production lines to manufactures globally. Our engineering staff has technical expertise, a diverse knowledge base, and has built thousands of integrated automation systems over the last 20+ years. Not only does MWES provide the new equipment, but also new process development, training, support, service, maintenance, and retrofits for all of a factory’s manufacturing equipment. Our design and build solutions include: customized robots, specialized End of Arm Tools (EOAT), cable solutions, vision systems, safety enclosures, process monitoring, control systems, and automation systems.
Content Filed Under:
Industry:
Automotive
Automotive
Application:
Assembly
and Material Handling
Assembly
and Material Handling
Automated Knurling Machine
POSTED 01/09/2014
The Challenge
- Machine must be capable of programming four (4) different part numbers
- Must process one (1) part every 2 seconds
- Compact design to optimize floor space
- Capable to flip parts that are loaded up-side-down
- Must have sensors to detect radial orientation of part on in-feed conveyor to insure correct placement in dial table nest
- Designed for high pressure and high forces exerted by the knurling process
-
Built-in quality assurance throughout the knurling and handling process to detect defects on top & bottom surfaces such as:
- Missing features
- Slug marks
- Missing holes
- Missing or additional material
-
Ability to log failure information to an operator interface including:
- Part number
- Defect type
- Quantity of each type of defect
- Time and date stamps
- Heavy duty common base for simple install and portability
- Fanuc LR Mate 200iD robot and R-30iB controller with Fanuc 2D vision camera for part orientation identification on in-feed pick-up locations and placement on dial process system
-
Robotic End of Arm Tool
- Magnetic gripper
- Sensors
- In-feed Flip Station with two (2) position shuttle escapement
- Two (2) TOX 30-ton, air over oil, presses
- Twelve (12) position, servo driven, dial table
- Three (3) position, servo driven, out-feed flip station
- Out-feed conveyor
- Four (4) camera PPT vision system
-
Control System
- Electrical enclosure
- Servo motor control system
- PLC with EtherNet IP communication
- Robot to PLC interface
- Operator HMI display
- Arc flash compliance
- Safety system and enclosure with components, programming, and layout per ISO 13849-1:2006 Category 3 safety guidelines and ANSI/RIA R15.06-1999 specifications
- Complete electrical and mechanical engineering design
- Complete robot, vision, PLC, and HMI programming
- Complete electrical and mechanical fabrication, assembly, and system test
- On-site installation, start-up, and acceptance testing
- Technical training for operators, engineering, and maintenance
- Increased productivity- machine can run 1800 parts/hour
- Increased productivity - less tooling than previous machine equals faster changeover between parts
- Decreased maintenance - fewer moving parts to maintain than previous machine & less tooling to maintain
- Increased reliability and uptime - Mechanically driven, hard tooled, walking beam replaced with programmable 6-axis servo robot and two (2) programmable servo driven dial tables
- Increased floor space - robotic solution requires 20% less floor space
- Improved quality- multiple sensors are able to detect failure and immediately notify the operator
- Failure reporting- automatic data logging and tracking of failures