Bott asked us to design and manufacture a special purpose machine that would automatically assemble, weld and bend a finished tool hook in a 3 second time frame further more the machine needed to be able to make over 15 variations of the part with 5 rod lengths and 3 back plate styles with minimal change over between parts.
Our solution consisted of splitting the machine down into its individual processes: pin sorting and loading, plate loading, measuring, welding, bending, cooling and ejecting. These stations were all developed in isolation before being coupled with a jig system to convey the components through the entire process. In order to meet the tight production time constraints all stations had to perform their tasks simultaneously.
This required a true mechatronic integration of pneumatic, hydraulic and electric actuators. The machine has 20 pneumatic cylinders, 2 hydraulic cylinders, 5 variable speed motors and 3 servo axes all synchronised to millisecond accuracy using Sharp and Tappin’s bespoke designed control system.
The completed machine delivered all the requirements and has been in use continuously for last 3 years producing well over 1 million parts to date while and saving a significant yearly manufacturing cost and increasing production capability.
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