MU Project (Group 1)
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MU Project (Group 1) Automatic Epoxy Dispensing Machine Collaboration with Standard Success Groups Ltd. Introduction. Collaborate with Standard Success Groups Limited Design an epoxy filling machine incorporated in production of Toroidal Transformer Dimension of transformer

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


Introduction

  • Collaborate with Standard Success Groups Limited

  • Design an epoxy filling machine incorporated in production of Toroidal Transformer

  • Dimension of transformer

    • Outer Diameter: 80~140 mm

    • Overall Height: 40~110 mm


Introduction (Con’d)

  • 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


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


Objectives of design

  • To enhance productivity and efficiency

  • To improve the quality of products

  • To simplify labour workflow by automatic control


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 factory’s side

  • Presenting to the personnel of our preliminary design


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


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


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.


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.


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


Dispenser


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


Design Alternatives (Conveyer)

Disadvantages

  • The system may require a lot of servo-motors and sensors

  • Relative low production rate (single line production)

  • Expensive


Outlook of the whole system

Dispenser System

Turntable


Filling of Epoxy

Epoxy Container

Tank

Dispenser Valve Unit


Dispenser valve unit

Cylinder


Closing of Hole

Opening of Hole


Epoxy Output

Pressure

Epoxy Injector

(Changeable)


Turntable Rotate


Our Prototype


Our Prototype


Cost Calculation

Total: $ 20,075.4


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


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.


Manufacturing (3)

  • Sheet metal workshop

    • To fold the PLC control box.

  • Welding workshop

    • To weld the tank of dispenser.


Manufacturing (4)

  • Turntable main mechanism is mainly made in the CNC workshop

    • Bearing covers

    • Shaft


Manufacturing (5)

  • Turntable main mechanism includes different sizes of bearing

  • Fitting bearings require much more accuracy

  • CNC machining can produce more reliable parts


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.


Sequence


PLC I/O diagram


Circuit Diagram


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


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


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


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


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


Division of work


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


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


Conclusion

  • From IC Centre

    Tell us, we will forget;

    Show us, we will remember;

    Let us do it, we will understand.

    告訴我,我會忘記

    讓我看,我會記起

    讓我做,我會明白


Automatic Epoxy Dispensing Machine


The End

Thank you!


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