The Challenge

 

• Machine automation system must be capable of being programmed for four (4) different part numbers

• Must achieve and automated process speed of one (1) 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 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 & 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

 

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The Solution

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

• Heavy duty common base for simple install 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

  • 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

• Midwest engineered systems 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

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​Impact to the Customer

 

The delivered automated knurling machine provided the customer with process improvements such as:

• Increased productivity – machine can run 1800 parts/hour

• Less tooling than previous machine for faster changeover between parts

• Decreased maintenance – fewer moving parts to wear than previous machine & less tooling to maintain

• Increased reliability and up-time – Mechanically driven, hard tooled, walking beam replaced with programmable 6-axis servo robot and two (2) programmable servo driven dial tables

• Increased floor space – MWES Robotic solution requires 20% less floor space

• Improved quality – Multiple sensors are able to detect failures and immediately notify the operator

• Failure reporting – Automatic data logging and tracking of failures