Automated Knurling Machine

THE CHALLENGE

This firm sought out MWES to robotically automate a valve plate knurling manufacturing process for a high-volume automotive industry application. The robotic system had to be able to operate within the high pressure and high forces exerted by the knurling process. As well as perform all the operations with speed and quality assurance in mind. The automated production system had to be able to autonomously log part failure information to an operator interface.

The firm brought forth a long list of challenges that MWES had to achieve:

• The machine automation system must be capable of being programmed for four different part numbers
• Must achieve an automated process speed of one part every 2 seconds
• The automated work cell must have a compact design to optimize floor space
• The automated production system must be capable of flipping parts that are loaded up-side-down
• It must have sensors to detect the radial orientation of a part on the in-feed conveyor to insure correct orientation in the dial table nest
• The system must be able to operate within the high pressure and high forces exerted by the knurling process

Built-in quality assurance throughout the knurling and handling process. The automation system must also detect defects on the top and bottom surfaces of the part, such as:

• Missing features
• Slug marks
• Missing holes
• Missing or additional material

The automated production system must have the ability to log part failure information to an operator interface including:

• Part number
• Defect type
• Quantity of each type of defect
• Time and date stamps

THE SOLUTION

The automation solution MWES provided our customer with a compact robot cell that tends a pair of TOX 30-ton presses that are capable of handling four different part types. The robot is equipped with a magnetic gripper and 2D vision camera end-of-arm tool (EOAT). The system is equipped with a four-camera PPT vision system to detect the radial orientation of a part on the infeed conveyor to ensure correct orientation in the twelve-position dial table nest and flip any parts that are loaded upside-down.

Lastly, the system has built-in quality assurance throughout the knurling and handling process and the automation system can detect a wide variety of defects on the top and bottom surfaces of the part. The entire robot cell follows the safety guidelines of ISO 13849-1:2006 Category 3 and ANSI/RIA R15.06-1999 specifications.

After a full evaluation of the project’s challenges and goals, Midwest Engineered Systems designed and built the customer a complete automated solution, which included:

• Heavy-duty common base for simple installation and portability
• Fanuc LR Mate 200iD industrial robot and R-30iB robot controller with Fanuc 2D robotic vision camera for part orientation identification on in-feed pick-up locations and placement on dial process system
• Robotic End of Arm Tool with a magnetic gripper and sensors
• In-feed Flip Station with two-position shuttle escapement
• Two TOX 30-ton, air over oil, presses
• Twelve positions, servo-driven, dial table
• Three-position, servo-driven, out-feed flip station
• Out-feed conveyor
• Four-camera PPT vision system
• The 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
• MWES provided 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 be MWES for operators, engineering, and maintenance

IMPACT TO THE CUSTOMER

With the successful integration of the automated knurling machine MWES provided, our customer achieved increased productivity of 1800 parts per hour (one part every 2 seconds) all the while requiring 20% less floor space. Additionally, multiple sensors afforded them improved quality by detecting failures and immediately notifying the operator when issues arose and the system would automatically log and track the failures. Lastly, the robotic system utilizes fewer moving parts than the previous machine and less tooling to maintain, which in turn, increases the reliability and up-time of the process.

Midwest Engineered Systems has a wide range of experience in building custom robotically automated machines. If you’re looking to improve your manufacturing throughput, we have the knowledge and experience to make the project a success.

Contact us to learn how Midwest Engineered Systems can automate even your most complex and challenging operations today!