MU Project (Group 1) Automatic Epoxy Dispensing Machine Collaboration with Standard Success Groups Ltd. Chan Lai Yin 02061668d Law Tsz Fung 02061668d Lee Kit Chun 03401700d Li Wai Kin 03381120d Ng Chin Yiu 03337129d Wong Ching Han g 03015719d Wong Ching Pon g 03352040d Project Ir Robert Tam
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MU Project (Group 1) Automatic Epoxy Dispensing Machine Collaboration with Standard Success Groups Ltd. Chan Lai Yin02061668d Law Tsz Fung02061668d Lee.
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MU Project (Group 1)Automatic Epoxy Dispensing MachineCollaboration with Standard Success Groups Ltd.Chan Lai Yin 02061668dLaw Tsz Fung 02061668dLee Kit Chun 03401700dLi Wai Kin 03381120dNg Chin Yiu 03337129dWong Ching Hang 03015719dWong Ching Pong 03352040d
Project Supervisor Ir Robert Tam Technical Officer Mr Henry Wong
Mr C.K.Chiu
Introduction Collaborate with Standard Success
Groups Limited Design an epoxy filling machine
incorporated in production of Toroidal Transformer
Dimension of transformer1. Outer Diameter: 80~140 mm2. 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
1. To enhance productivity and efficiency
2. To improve the quality of products
3. 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
1. Locate the transformer (2) onto the fixture
2. Fill-in the mixed epoxy into tank
3. Filling time and volume of epoxy controlled by PLC automatically into the cavity
4. Take out the fixture from turntable
5. 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 2Specification 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 angleThe 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 systemDispenser System
Turntable
Filling of Epoxy
Tank
Epoxy Container
Dispenser Valve Unit
Dispenser valve unit
Cylinder
Closing of Hole
Opening of Hole
Epoxy Output
Epoxy Injector(Changeable)
Pressure
Turntable Rotate
Our Prototype
Our Prototype
Cost Calculation
Parts Prices
Mechanical parts Yee Fu Engineering & Trading Co.
$ 7,030.4
Pneumatic parts and control units
SMC Mitsubishi
$ 10,286.8
Electrical parts RS Hong Kong
$ 2,758.2
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 panelThe 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
Name Responsibility
Chan Lai Yin, Lee Kit Chun, Li Wai Kin, Wong Ching Hang
Design and manufacturing of dispenser and turntable
Documentation, Website
Law Tsz Fung, Ng Chin Yiu, Wong Ching Pong
Design and manufacturing of turntable
Control system
The whole group Presentation
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.