Robots boost 2K operation

04 May 2010

2K Polymer Systems is meeting increased product demand and cutting response times with an automated robotic production cell solution from Aylesbury Automation. The robotic solution check weighs and palletises cartridges ready for transfer to the next process.

The Alfreton, UK based company supplies grouts, mortars, fillers and adhesives for the private label products market, providing a range of anchoring, sealing, bonding, filling and repair solutions. Its speciality is in chemical mortars and resin-based compounds.

Aylesbury Automation has helped to improve quality management and minimise manual handling. After filling, the cartridges are moved from the outlet of the cartridge filling and assembly machine by a DENSO VS-6577, 6 axis robot. The robot is equipped with a range of grippers to ensure all different styles of cartridges can be picked. The robot places each cartridge into a purpose-built weigh station. The check weight of each style of cartridge is selected from the DENSO Robot Teach Pendant, which is also the system’s HMI.

Cartridges which pass the check weigh station’s tolerance limits are placed systematically into a grey storage container. Rejected cartridges are placed in an adjacent reject bin. To minimise floor space, product storage containers are fed using a powered “L” shaped conveyor.

When each container is filled it is automatically discharged from the loading position and the next empty container transferred ready for processing. To maximise process efficiency filled cartridges are transferred to a holding station during storage container changeover.

There is no PLC in the production cell, all the machine’s functions are co-ordinated by the multi-tasking robot controller using Devicenet I/O, and this delivers a considerable cost saving. Six background tasks operate to control 256 I/O points and all status and error messages are shown on the robot HMI.

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