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Contents
Problem Statement
Plastic Injection moulding
Robotics
Automation 2012 visit & IATF 2013
Design and analysis
Pneumatics and electricals
Fabrication
Problem Statement
1. To Enhance the productivity in IMM industry using
automation and resolve issues regarding workers.
2. To perform pick and place operation within 8 seconds from
IMM to Granulator.
Purpose of Project
1.
2.
3.
4.
5.
6.
7.
8.
Consistency
Fast Cycle time
Less Labor Cost
Product Hygiene
Safety Issue
2nd level Automation
Continuous Operation
Productivity
Abstract
Electro-pneumatic robot for automation in plastic IMM
Methodology
1. Robot models and IMM study
2. Exhibitions
3. Industry survey
4. Brain storming
5. Pneumatics and Electricals.
6. Design and material selection
7. Analysis
8. Design review and synthesis
9. Fabrication
10. Testing and results
Injection Weight
PS. g (oz)
25 Arburg
221
32 (1.13)
40 Kawaguchi
275 x 245
*55 Arburg
320 x 320
*88 Arburg
370 x 370
*110 Arburg
420 x 420
125 Kawaguchi
435 x 375
140 Kawaguchi
435 x 375
175 Kawaguchi
445 x 445
*220 Sumitomo
610 x 560
265 Kawaguchi
550 x 550
*280 Sumitomo
685 x 635
300 Dongshin
685 x 580
73 (2.57)
150 - 250
Opening Stroke
Max (mm)
200
230
78 (2.5)
min 225
350
89 (3.4)
min 200
450
153 (5.9)
min 250
575
226 (7.97)
260 (9.17)
372 (13.1)
532 (18.8)
649 (22.9)
733 (25.9)
970 (34.1)
180 - 400
180 - 400
250 - 450
250 - 580
200 - 550
300 - 620
300 - 680
355
355
400
510
500
580
600
Proposed designs
1. Guide way cartesian model
2. Articulated type (scara,revolute)
3. Cartesian type
Types of products :
Simple Operation
Sprue Picking
with Part
Dropping
Part Removal
Part removal
with the sprue
or without the
sprue
5. Sepro S3 picker
2. Yushin Hop 5
7. Phoenix
3. Sailor RX-8
Arrival of Raw
materials & mould
Start
End
Dispatch of Component
Mould on moulding
machine using hoist
Is product
defective?
No
Component package
and storage
Moulded components
for finishing
Drafted image
Cylinder selection
Cylinder selection :
Mechanisms
1.
2.
3.
4.
5.
6.
Design considerations :
We have used factor of safety of above 3 everywhere except in case
of gear we have fos = 2.4
Our design is safe at 8 bar pressure. and gear pair fos is 1.2 at 8 bars.
Design innovations
Mitre bevel gear eliminated the need for
wrist rotation of gripper plus reduced 1
movement of vertical cylinder.
Arc bracket provides rotation on either
side.
Self made slider from nylon on
Aluminium was made.
Gripper was developed from compact
cylinder.
Material selection :
1. Cast Iron
It has good damping property and less density than steel but costly and not readily
available. Density= 7250 kg/m^3.
2. Mild Steel
It has compartively less damping but good welding characteristics and cheap plus
readily available. Density= 7850 kg/m^3
3. Aluminium
Light weight with hardness and stiffness. Easy riveting possible.
Density = 2710 kg/m^3
4. Nylon
Ansys analysis
Critical components like horizontal shaft,
arc bracket , base plate were examined
for static and dynamic failure.
Fos was safe for design made.
Electro-pneumatic circuit :
The sensing time of reed switch is 1 millisecond.
Reeds operate at 24 V DC
Solenoid valves operate at 24 V DC with 104 mA current.
As relay logic and logic gates could not be built , we choose controller.
So A micro controller 8052 was used taking sensors as inputs (8) and
solenoids as output (8) . Reset function was provided in case of sudden stops.
C programming successfully implemented the required logic on controller.
Gripper
1. Mechanical 2 finger gripper
2. Vaccum gripper
Robot Specifications
1.Payload : kg
2. Weight : 22.4 kg
3. Cost : 51,200 uptil now
4. Control method : Micro controller
5. Material : Mild steel for foundation, Aluminium for manipulator
6. Configuration : Semi- cylindrical (swing arm)
7. DOFs : 4 (3 cylinder + 1 gripper)
8. Actuator : Mitre bevel gear rotation using swing cylinder
9. Kick stroke : Linear nylon guide rail.
10. Vertical stroke : Gripper with guide way
11.M/c tonnage : 30 to 55 tons
12. Power supply : 24 V DC ,1 A
13. Air consumption :
14. Swing angle : 50 to 90 deg both sides.
15 .Max pressure: 6 bar
16. Working pressure: 2 to 4 bar
17. Overall cycle time : within 8 secs.
Model no.
Specification /product
Qty
Cost
Total
1
2
3
4
5
6
7
8
9
10
11
12
13
A52020080O
A52025080O
A52016160O
DS254SS60-W
GR5105006
WP2210650
MS022
AA022
AP010
AP008
AM1016
AM1020
AM1025
DA 20 x 80 Cyl.(Mag) Basic
DA 25 x 50 Cyl.(Mag) Basic
DA 16 x 160 Cyl.(Mag) Basic
1/8 -5/2,24V DC Double Sol. valve
Flow control valve 1/8 x Dia 6
Male elbow Dia 6 x 1/8
DOUBLE FOOT MOUNTING (DIA 20,DIA 25)
CLEVIS FOOT BRACKET (DIA 20,DIA 25)
ROD END SPHERICAL EYE (DIA 25,DIA 32)
ROD END SPHERICAL EYE (DIA 20)
Reed switch with clamp (A52016)
Reed switch with clamp (A52020)
Reed switch with clamp (A52025)
1
1
1
4
6
8
1
1
2
1
2
2
2
1243
1323
1176
2030
224
43
234
148
560
511
451
451
451
1243
1323
1176
8120
1344
344
234
148
1120
511
902
902
902
14
15
16
17
18
19
20
21
22
23
24
FRCLM146234/W
WP2110851
M0030104
ASC0161
WP2110852
A2G02
WH00B08
WH00B06
1
2
1
2
1
1
2
8
1
2
1
2649
36
1355
83
41
171
56
31
2649
72
1355
166
41
171
112
248
0
0
135
WC1
Total
135
23218
Cylinder A+
Cylinder B+
Gripper C+
Cylinder BCylinder ACylinder D+
Gripper CCylinder D-
Fabrication operation
1. Milling
2. Boring
3. Tapping
4. Welding
5. Grinding
6. Drilling
7. Turning and Facing
8. Laser cutting
9. Hack saw cutting
10. Rivetting
11. Surface finishing
12. Grub holes
Final Assembly
All components were joint and made ready.
Piping was done properly along with sensor
wiring connection through insulation
casing.
Manifold and controller housing was done.
Gauge and frc unit was interfaced then.
Thank You