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Epoxy Dispenser Machine

Epoxy Dispenser Machine. Dispenser Part. Design Objectives. To increase the productivity To improve the quality of products To simplify human work by automatic control. Design Considerations. Easy to assembly Easy to clean Easy to have maintenance User friendly Economical

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Epoxy Dispenser Machine

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  1. Epoxy Dispenser Machine Dispenser Part

  2. Design Objectives • To increase the productivity • To improve the quality of products • To simplify human work by automatic control

  3. Design Considerations • Easy to assembly • Easy to clean • Easy to have maintenance • User friendly • Economical • Effective production

  4. Marketing Products 5000桌上型 雙液自動混合機 6000型 雙液自動混合機 7000型 雙液自動混合機

  5. Design 1 • Specification of Design 1: • Three dispensing heads • Easy to clean through one main channel • Simple to just fill one mixing tank

  6. Design 1 • Use one tank then diversify three syringe heads to fill  • Hard to maintain the same pressure and flow amount of each head • Imperfect product would be the result

  7. 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

  8. Design 2  • The flow of epoxy may not be easy without the sliding angle • The rivet pattern will be loosened by frequent use.

  9. 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

  10. Operation Mixing of resin and hardener in a tank Pouring the epoxy into the rubber tank Control the PLC to open the valve Appropriate amount of epoxy is ejected to fill the coil

  11. Cost Estimation • Regulator/ Pressure gauge ~$155/pc • Safety valve ~$100/pc • Plastic tank ~$50/pc • Surface tank (with cover and lock) ~$250/pc • Screw ~$50/100pc • Disposable syringe ~$125/100pc • Rubber ring ~$50/25pc • Stainless Steel ~$7/lb • Gas cylinder ~$200/pc

  12. Epoxy Dispenser Machine X-Y table Part

  13. X-Y table Objectives • Provide one degree of freedom • Precise movement for dispensing • Sensors detected the positions • Afford a loading of supporting 9 largest size transformers and the container • Controlled by PLC

  14. Available Product on the market • Conveyor • x-y table in Lathe machine

  15. Comparison of the products • Conveyor -lower cost -suitable for continuous process -using servo-motor and controlled by PLC -inflexible for different kinds of transformers

  16. Conveyor cost estimation http://www.materialflow.com/Low_Profile_Mini_Belt_Conveyors.htm#RLP

  17. x-y table in the Lathe machine -expensive -using servo-motor and controlled by PLC -suitable for all kinds of transformers by change the container

  18. X-Y table cost estimation • MICROLUX X-Y TABLE ATTACHMENT • Item Number: 82389 • List Price US$129.95 • Specifications (inches): • Table Size: 8-1/4 L x 2-3/4 D • Overall Size: 10-1/2 L x 7-1/2 D x 1-11/16 H • Base Size: 3-3/4 x 5-1/2 • X Direction Travel: 5-1/4 • Y Direction Travel: 1-3/4 • Dial Graduations: .001; .050 per revolution http://www.ares-server.com/Ares/ Ares.asp?MerchantID=RET01229&Action=Catalog&Type=Product&ID=82389

  19. Our Design similar to product 2 • Upon the above comparison, we choose product 2. -not for continuous process -suitable for various types of transformers -precise position controlling by using servo-motor and PLC

  20. X-Y table and PLCestimated cost • X-y table ~$3000 • PLC ~$2000 • Profile ~$200/each

  21. Maximum Loading • 9 transformers for the largest one • Total weight of transformer: 1.468kg X 9 pieces =13.212 kg • The largest volume filled with epoxy = 142.5 • Total weight of epoxy filled into the space = 1.833 kg • The weight of the fixture = 7.5kg • Therefore, the predicted weight is about 22.545 kg

  22. Working Procedure-1

  23. Working Procedure-2

  24. Working Procedure-3

  25. Working Procedure-4

  26. Working Procedure-5

  27. Working Procedure-6

  28. Working Procedure-7

  29. Working Procedure-8

  30. Working Procedure-9

  31. Working Procedure-10

  32. Working Procedure-11

  33. Limitation of our design • Only two sizes of transformer would be prepared for the operation. • Translation of the transformers is needed. • Air bubble may be formed during the process.

  34. Preparation work for fixture • Install the fixture for the desired type of transformer onto the x-y table • Place the transformers on the fixture

  35. Normal Operation Steps • The fixture moves from the initial position • The fixture moves along the x-table designed to where to dispense • The valve would be opened by the signals given by PLC.

  36. Normal Operation Steps • The epoxy will start to flow from the dispenser to fill the inner core of the transformers. • The PLC would give the signal to control the valve and stop the dispensing process.

  37. Normal Operation Steps • Upon the dimensions of the fixtures, the fixture will move and stop several times to fill all transformers on the fixture with epoxy

  38. Normal Operation Steps • After all transformers are filled, the fixture will move to the end of the x-table. • The transformers will then be available for the workers taking to the oven.

  39. Specification estimation • Filling time: 30s / each transformer • Cleaning time: 15 mins • Setup time: 5 mins

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