MU Project Group 1 Automatic Epoxy Dispensing Machine Collaboration with Standard Success Groups Ltd

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MU Project (Group 1)Automatic Epoxy Dispensing
MachineCollaboration with Standard Success
Groups Ltd.
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Introduction

• Collaborate with Standard Success Groups Limited
• Design an epoxy filling machine incorporated in
  production of Toroidal Transformer
• Dimension of transformer
• Outer Diameter 80140 mm
• Overall Height 40110 mm

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Introduction (Cond)

• Formula of epoxy 80 of epoxy plus 20 curing
  agent
• Average mixing time 2 min
• Average filling time 19.95 m3 per second
• Leakage of epoxy from the fixture

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Scope of Project

• Design an epoxy filling machine by using PLC
• Design the appropriate fixture of holding
  transformers into position
• Construct the fixture and machine

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Objectives of design

• To enhance productivity and efficiency
• To improve the quality of products
• To simplify labour workflow by automatic control

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Factory Visit on 1/4/2006

• Objective
• Deeper understanding of Background of Factory and
  production process
• Technical Difficulties for reliability
• Possible Defect
• Realize the expectation from factorys side
• Presenting to the personnel of our preliminary
  design

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Design Criteria

• Easy to assembly, clean and undergo maintenance
  or overhaul activities
• User friendly
• Economical of time and money in manufacturing and
  production
• Effective in production

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Process Flow of Machine

• Locate the transformer (2) onto the fixture
• Fill-in the mixed epoxy into tank
• Filling time and volume of epoxy controlled by
  PLC automatically into the cavity
• Take out the fixture from turntable
• Put the fixture into oven

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Design AlternativesDesign 1

• Specification of Design 1
• Three dispensing heads.
• Easy to clean through one main channel.
• Simple to just fill one mixing tank.
• ?
• Hard to maintain the same pressure and flow
  amount of each head.
• Imperfect product would be the result.

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Design 2

• Specification of Design 2
• Easy to assembly by rivet system
• Easy to clean as using plastic bag to wrap the
  surface
• Easy to disassembly by loosening the rivet for
  cleaning
• ?
• The flow of epoxy may not be easy without the
  sliding angle
• The rivet pattern will be loosened by frequent
  use.

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Design 3

• Specification of Design 3
• Modification of Design 2
• Easy flow for the epoxy with a sliding angle in
  the tank
• Reliable screw system for easy assembly and
  disassembly

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Dispenser
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Design Alternatives (Conveyer)

• Advantages
• Continuous processing (can link with other
  machines)
• Easy to assembly and make adjustments
• The availability of the conveyer is high in the
  market

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Design Alternatives (Conveyer)

• Disadvantages
• The system may require a lot of servo-motors and
  sensors
• Relative low production rate (single line
  production)
• Expensive

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Outlook of the whole system
Dispenser System
Turntable
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Filling of Epoxy
Epoxy Container
Tank
Dispenser Valve Unit
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Dispenser valve unit
Cylinder
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Closing of Hole
Opening of Hole
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Epoxy Output
Pressure
Epoxy Injector (Changeable)
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Turntable Rotate
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Our Prototype
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Our Prototype
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Cost Calculation
Total 20,075.4
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Manufacturing (MMU)

• These parts are mainly made by cutting, milling
  and turning machines in the MMU workshop.
• Aluminum profile cutting
• Blocks milling
• Discs and some parts turning
• Drilling holes
• Taping

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Manufacturing (2)

• High surface finishing and low tolerance Parts
  are made in CNC workshop.
• Bearing covers turning
• Plates drilling
• Complicated shape discs are made by wire cutting
  machine.

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Manufacturing (3)

• Sheet metal workshop
• To fold the PLC control box.
• Welding workshop
• To weld the tank of dispenser.

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Manufacturing (4)

• Turntable main mechanism is mainly made in the
  CNC workshop
• Bearing covers
• Shaft

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Manufacturing (5)

• Turntable main mechanism includes different sizes
  of bearing
• Fitting bearings require much more accuracy
• CNC machining can produce more reliable parts

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Manufacturing techniques

• All parts edge should be removed to be chamber.
• Use grinding machine to unify same parts height
  and increase the surface finishing.
• To turn and mill stainless steel parts, using
  carbon tools is recommended instead of high speed
  steel tools.

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Sequence
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PLC I/O diagram
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Circuit Diagram
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Touch panel

• Software can create the screen and then input the
  screen to the PLC.
• Preset instructions will allow user to control
  the machine by panel buttons

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Touch panel

• The keyboard page helps user to change the time
  by panel
• Using the PLC memory to save the value and then
  for the further operation

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Planning (25Feb-29Apr)

• Analyzed the project
• Visited the Standard Success Groups Ltd.
• Estimated the budget
• Proposed the design ideas
• Drew the design ideas by using CAD software
• Presentation to the client
• Made changes on the design to meet clients'
  requirements
• Improved our design and inform our clients
• Training on the PLC control system
• Documentation (BOM)
• Sent BOM to preserve materials for manufacturing

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Planning (24May-28Jun)

• 24May-27May
• Preparing the profiles
• Amending the CAD drawing
• 29May-10Jun
• Manufacturing of the valve system for the
  dispensers
• Manufacturing of parts of the turntable
• Testing the PLC devices and writing the PLC
  program

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Planning (24May-28Jun)

• 12Jun-24Jun
• Manufacturing of the remaining parts of
  dispensers
• Manufacturing of the main shaft for turntable
• Manufacturing of the control box
• Program Debugging
• Fine tuning of the manufactured parts
• 26Jun-28Jun
• Fine tuning of the manufactured parts and PLC
  system
• Assembly of the whole device
• Preparing stuff for presentation

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Division of work
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Learning Outcome

• We are familiar with
• Dispensing system
• Parts for dispensing function
• PLC Control system
• PLC parts
• Selection of the suitable candidates for design
• Programming
• Testing

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Learning Outcome

• Problem solving skills
• Solve the problem between theory and reality
• Contingency plan
• Co-operation skills
• Communication among our group
• Different processes undergone at the same time
• Communication between each workshop

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Conclusion

• From IC Centre
• Tell us, we will forget
• Show us, we will remember
• Let us do it, we will understand.
• ???,????
• ???,????
• ???,????

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Automatic Epoxy Dispensing Machine
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The End

• Thank you!

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• Question and Answer