At the customer's request, improvements and upgrades are needed for the customer's factory workshop. The specifics are as follows:
1. Improve the company's automation level and accelerate production efficiency;
2. Reduce redundant personnel and increase company revenue;
3. Reduce labor risks and provide maximum assurance for safe production.
Process Plan:
1. Products are completely demolded from the casting machine via a vibration device;
2. After demolding, they are placed on a conveyor belt via a receiving device;
3. The conveyor belt transports the workpiece to the deburring station, where a deburring device performs positioning and deburring, powered by a hydraulic cylinder.
4. After deburring, the conveyor belt continues to operate, carrying the workpiece through a passivating tank for dipping, and then to the gripping station;
5. A robotic arm grips the workpiece and performs palletizing. After completing a pallet stack, the weighing system outputs data to the inkjet printer. The lifting conveyor rises, and the pallet stack moves forward. Simultaneously, a temperature probe checks the temperature of the stack, ensuring it has cooled to below 80℃ before packaging;
6. After the pallet stack reaches the packaging station, a lifting device raises and rotates it, and the automatic packaging machine performs packaging;
7. After packaging, the stack enters the inkjet printing process, and the inkjet printer prints according to the received weight;
8. After inkjet printing, the stack flows into the temporary storage station, awaiting transport by forklift;
9. The cycle repeats.
ABB IRB460-110 Robot Parameters
Robot characteristics: High speed, short cycle time; long lifespan, short repair time; high precision, high load capacity.
Suitable for gripping square workpieces of different sizes. Adjustments are made according to the actual situation, perfectly combining with the robot to complete workpiece gripping.
Vibration Device:
The vibration device is driven by a pneumatic cylinder, vertically impacting the edge of the mold. Each mold can vibrate 4-5 times to ensure complete demolding of the workpiece.
Receiving Device:
The receiving device has been modified from its original design. It now receives one workpiece at a time instead of five, with other aspects remaining unchanged.
Deburring Device:
The deburring device uses a hydraulic cylinder-driven scraper to remove burrs from the workpiece. A stop bar aligns the workpiece, making it parallel to the scraper. After the workpiece is clamped by a fixing device, deburring is performed.
Weighing and Palletizing Area:
The palletizer places the dipped workpieces on the weighing device. After completing a pallet stack, the weighing device reads the data and transmits it to the controller. The lifting conveyor rises, transporting the stack to the next station.
Automatic Packaging Machine:
When palletizing, a lifting and rotating device raises and rotates the stack by 90°. The packaging machine begins packaging, then returns to its original position for cross-packaging. After packaging, the stack descends and is transported to the inkjet printing process by the conveyor belt.
Production Efficiency Explanation
1. In this plan, the dipping method uses a through-type dipping method, replacing the original robotic gripping and dipping, saving gripping time and improving efficiency.
2. Based on the customer's requirement of 25 tons per hour, the single-piece production cycle is 7.3 s/piece.
3. Deburring uses a hydraulic cylinder drive. Removing burrs from one workpiece takes about 6 seconds. Because it runs concurrently with workpiece receiving, a time less than 7.3 seconds is sufficient.
4. The robot uses an ABB high-speed palletizer, which can meet the production cycle requirements.
