Cube Assembly Pro Mechatronics system
- 1. CUBE ASSEMBLY PRO – MECHATRONICS SYSTEM
- 2. CUBE ASSEMBLY PRO : This compact mechatronic system depicts a complete structured automatized assembly process. Here, the manufacturing steps of feeding, material testing, transporting and handling, pinning, pressing and storing are realized. The applied workpieces are cube halves of aluminum and plastic. The cube halves are being pinned automatically before the pressing process. To achieve this, special Functional Units are applied for turning of the halves repeatedly and to insert the pins.
- 4. BLOCK DIAGRAM: FRL/ Service Unit Magazine Unit Long Conveyor Belt Testing Unit Handling Unit Rotary Unit Pinning Unit Portal Pneumatic Press Short Conveyor Belt Handling Unit/ Robotic Arm ASRS
- 5. BLOCK DIAGRAM: Magazine Unit Long Conveyor Belt Robotic Arm Pinning unit Pneumatic Press Robotic Arm Short Conveyor belt Robotic Arm Automatic Storage and Retrieval System (ASRS) unit 4 1 2 3 Testing Unit
- 6. COMPONENTS OF CUBE ASSEMBLY Trolley 1: Conveyor Station • Service unit • Magazine unit • Long Conveyor Belt • Testing unit • Operating Panel Trolley 2: Processing Station • Handling unit/ Robotic arm • Rotating unit • Pinning unit • Portal • Pneumatic Press • Short Conveyor Belt Trolley 3: ASRS Station • Handling unit/Robotic arm • ASRS (automatic storage and retrieval system)
- 7. TROLLEY 1: CONVEYOR STATION Pre-pinned cube halves of aluminum and plastic are fed onto the conveyor belt by the stack magazine. The testing unit checks, if the delivered halves are the correct ones. The halves are transported to the end of the belt in order to be picked up by Station 2. Applied Technology: • Distribution of workpiece • Motor controlling • Conveying Technology • Sensorics • Identification of different workpieces • Sorting according to material characteristics • Optical fiber technology
- 8. TECHNICAL SPECIFICATION Technical Data: • Aluminium profile plate: 550 x 800 mm • Operating voltage: 24 VDC • Dimensions of belt: 680 x 50 mm PLC Requirements: • 17 digital PLC-inputs • 8 digital PLC-outputs Sensors: • 1 inductive sensor • 1 capacitive sensor • 1 optical sensor • 3 cylinder end switches • 1 micro end switch • 1 light scanner M3 with fiber optic amplifier Actuators: • 1 DC-motor 24 V • Reversing contactor circuit • 2 5/2-way valve • 2 double-acting pneumatic cylinders Operator Panel: with illuminated push-buttons and emergency switch. • Service Unit: 3/2-way hand valve • Connector Modules: with 2 x 8 bit connector plug
- 10. LONG CONVEYOR BELT & TESTING UNIT
- 11. OPERATING PANEL Sensors in testing unit Operating panel
- 12. TROLLEY 2: PROCESSING STATION The handling device is picking the cube halves from the belt of Station 1 and inserts them into the press. Here, the halves are being pressed by the cylinder and afterwards withdrawn again by the handling device in order to deliver them to the transportation axes of Station 3. Applied Technology: • Motor Controlling • Conveying Technology • Sensorics • Hydraulics • Pneumatics • Positioning • Handling; Connecting • Two-hand safety control
- 13. TECHNICAL SPECIFICATION Technical Data: • Aluminium profile plate: 550 x 800 mm • Operating voltage: 24 VDC • Dimensions of belt: 680 x 50 mm PLC Requirements: • 23 digital PLC-inputs • 16 digital PLC-outputs Sensors: • 8 cylinder end switches • 1 inductive sensor Actuators: • 1 DC-motor 24 V • 4 5/2-way valves • 5 double-acting pneumatic cylinders • 1 hydraulic cylinder Operator Panel: with illuminated push- buttons and emergency switch • Service Unit: 3/2-way hand valve • Connector Modules: with 2 x 8 bit connector plug
- 14. HANDLING UNIT/ ROBOTIC ARM
- 15. ROTATING UNIT It is designed for rotation of workpiece by 90°. The workpiece is placed in a take up and rotated by means of a pneumatic rotary cylinder. This unit inserts spring pins into workpiece. These pins are reserved in 2 magazines. An upright standing aluminum case half is placed with the opening in the direction of the magazine in the take up. The pneumatic cylinder of the take up presses the workpiece against the front side of the magazine. Opposite side-the pin insert moves forward and pushes two spring pins with the two ejectors towards the accommodation bores of the work piece halves. PINNING UNIT
- 16. PORTAL It removes the formed workpieces from the press and transports them further to the next station. The workpieces are taken up the sucker unit. Hence the sucker extends towards the bottom. After the take up the sucker returns to the upper area and the shuttle cylinder accomplishes the task of transporting the workpiece in horizontal direction. At the end of the stroke the workpiece is again placed down by the extended sucker unit. In this, workpiece can be formed with a force of approx. 220N. After the insertion of the workpieces, the workpieces are transported to press area. Then the safety door closes and the press cylinder begins to extend. After machining, the safety door opens and the workpieces are expelled from the work area and they are now ready for further transportation. PNEUMATIC PRESS
- 17. PNUEMATIC PRESS & PLC USED IN HANDLING UNIT
- 18. TROLLEY 3: ASRS STATION Applied Technology: • Positioning • Motor controlling • Conveying Technology • Sensorics • Logistics • Drive engineering with linear guide
- 19. TECHNICAL SPECIFICATION Technical Data: • Aluminum profile plate: 550 x 400 X 30mm • Weight: 15 kg. • Operating voltage: 24 VDC • Dimensions of belt: 680 x 50 mm Sensors: • 3 barrier light sensor • 8 micro switches • 2 cylinder switches (reed) Actuators: • 2 DC-motors 24 V • 1 5/2-way valve • 1 pneumatic cylinder Operator Panel: with illuminated push- buttons and emergency switch • Service Unit: 3/2-way hand valve • Connector Modules: with 2 x 8 bit connector plug PLC Requirements: • 22 digital PLC-inputs • 9 digital PLC-outputs
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