Because it opened in 1998, methods integrator Steven Douglas Corp. (SDC) has accomplished greater than 1,400 automation initiatives. Primarily based in Harmony, OH, the corporate has constructed automated meeting methods for myriad industries, together with shopper merchandise, automotive components, medical units, electronics, power and even aerospace.
“I’m continually impressed by the growth and adaptability of our team,” says Steve Belliveau, founder, CEO and chief technical advisor of SDC. “Over the years, their ability to learn and master new technologies has been instrumental in helping us deliver creative and robust machines.”
This automated meeting system employs a mixture of six-axis, SCARA and Cartesian robots. Photograph courtesy Steven Douglas Corp.
Just lately, a world producer of business know-how contacted SDC to construct an automatic system to assemble electrical security switches. SDC had already constructed a number of machines for this producer, so it was accustomed to how the integrator labored.
The brand new system had some distinctive necessities. First, the producer was launching a sensible manufacturing unit initiative, so the system would have to be geared up with industrial web of issues (IIoT) know-how. The producer additionally required the system to be geared up with robots from Yaskawa Motoman. The latter, not less than, was simple, since SDC is an authorized integrator for Motoman, in addition to Fanuc, Epson, Mecademic and ABB Robotics.
Different necessities included:
- Customized components feeding methods for greater than 5 components.
- Automated grease allotting.
- A handbook loading station with security mild curtains and stress switches.
- A number of take a look at and inspection stations.
The important thing parts of the system embrace:
- Six-axis and SCARA robots from Motoman.
- Computerized screwdrivers and nutrunners from Deprag.
- Vibratory bowl feeders and linear tracks from Bellco Feeders.
- Imaginative and prescient methods from Keyence.
- An HMI and PLC from Modicon.
This six-axis robotic performs two capabilities: selecting components from a bin and selecting components from a flex feeder. Photograph courtesy Steven Douglas Corp.
The system additionally accommodates a number of standardized, pre-engineered parts that had been designed and constructed by SDC. These embrace flex feeders, servo-driven pick-and-place models, and a rotary indexing ring. This minimized {custom} engineering work, eradicated main design dangers, and accelerated implementation.
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Vibratory bowls feed components to a linear monitor. Photograph courtesy Steven Douglas Corp.
Adaptive Workflow
On the first station, the six-axis robotic performs two capabilities: selecting components from a bin and selecting components from a flex feeder. The robotic locations these components right into a nest on the indexing ring.
Machine imaginative and prescient allows the robotic to acknowledge the orientation of components within the bin and decide them precisely. This protects money and time by eliminating the necessity to current the components in trays or different dunnage.
The flex feeder supplies a gentle circulate of pickable components. In contrast to conventional feeding methods that require mechanical changes, the flex feeder accommodates varied half geometries with out the necessity for tooling changeovers. This reduces setup time and will increase flexibility.
A imaginative and prescient system allows the robotic to find and decide components with minimal errors. An illuminated imaginative and prescient window ensures clear visibility and enhances the accuracy of the selecting operation. The feeder’s conveyor strategically strikes and reorients components to optimize pickability. Automated repositioning ensures that components are persistently offered in a great orientation for choosing.
A flex feeder supplies a gentle circulate of pickable components. Photograph courtesy Steven Douglas Corp.
Constructed to work with a wide range of robotic methods, the flex feeder helps high-speed pick-and-place purposes. Constructed-in accumulation and buffering optimize manufacturing circulate for max throughput.
The indexing ring is a custom-built, high-speed meeting machine platform. Its open design permits engineers to put course of modules each inside and out of doors the ring, which is predicated on a heavy metal body. Its sturdy development ensures long-lasting reliability with minimal upkeep. The ring facilitates fast tooling adjustments to accommodate completely different components and assemblies.
On the subsequent station, an computerized allotting system applies grease to the components.
Further components are put in at subsequent stations by an individual, a SCARA robotic, and servo-driven, multi-axis pick-and-place models.
An automatic system dispenses grease onto a number of components concurrently. Photograph courtesy Steven Douglas Corp.
Half placement and retention by way of the completely different meeting processes was important to machine operate and completed product high quality. The tolerance of the molded and fashioned components made SDC engineers refine acceleration and deceleration profiles and fine-tune meeting fixtures and different part-locating and retention units.
Computerized screwdriving and nutrunning methods set up fasteners from above and beneath the meeting. Initially, pneumatic cylinders had been used to maneuver the instruments up and down. Nonetheless, this proved inadequate to satisfy cycle time. A servo-driven linear actuator solved the issue and likewise improved accuracy.
The system additionally consists of 10-kilovolt hipot testing and a number of electrical and mechanical verification zones to make sure the security and compliance of each assembled half.
Seamless integration with the manufacturing unit’s IIoT ecosystem allows the producer to trace effectivity and monitor machine efficiency. Photograph courtesy Steven Douglas Corp.
Outcomes and Enterprise Impression
The system produces 3,000 assemblies per day with a 94 % effectivity price. It was designed to satisfy ultimate meeting line demand with out requiring time beyond regulation. Seamless integration with the manufacturing unit’s IIoT ecosystem allows the producer to trace effectivity and monitor machine efficiency.
The brand new machine replaces a legacy system that was in operation for greater than 40 years, providing not less than twice the throughput and near double the effectivity of the earlier gear.
For extra data on automated meeting methods, click on For extra data on robots, click on www.motoman.com.
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