How can robotic automation improve efficiency in manufacturing processes?

Our robotic automation solutions dramatically boost efficiency in manufacturing by enhancing speed, precision, and consistency. We focus on minimizing manual errors, accelerating production rates, and ensuring safety by handling repetitive and hazardous tasks.

What are the different types of robotic automation systems available for manufacturing applications?

We offer a range of robotic automation systems for manufacturing, including SCARA and Delta robots. SCARA robots are ideal for precision tasks requiring speed and compact design, while Delta robots excel in fast, repetitive actions like picking and placing.

What types of defects or issues can vision inspection systems detect in manufacturing?

Our vision inspection systems are adept at detecting dimensional inaccuracies, surface defects like scratches or dents, misalignments, and incorrect or missing components. They are also capable of verifying label accuracy, barcode readability, and color consistency.

What types of manufacturing tasks can be performed using a rotary indexing machine?Rotary indexing machines at Big Sky Engineering are highly versatile, designed to perform a range of precise manufacturing tasks. They are ideal for assembly, drilling, precision machining, and quality inspection. These machines excel in high-volume production environments, offering accuracy and repeatability.

Rotary indexing machines at Big Sky Engineering are highly versatile, designed to perform a range of precise manufacturing tasks. They are ideal for assembly, drilling, precision machining, and quality inspection. These machines excel in high-volume production environments, offering accuracy and repeatability.

4-Up Clamshell Packaging & Filling Verona, WI

SITUATION

The purchasing customer expressed the desire to expand its assembly operations for a fastener filling and packaging assembly line. The former antiquated process was slower using manual loading and packaging methods. The customer required the machine to be completely autonomous aside from loading the clamshells and product labels. The machine would require integrated labelers and a filling machine. The filling machine would be adaptable for multiple screw types.

OPPORTUNITY & IMPLEMENTATION

The proposed and final stations include:

Denester- The Denester station picks the thermoforms from the in-feed magazine. The thermoforms are placed in the machine’s indexer and places the cap parts into the rotating index dial.
Filling Station- The integrated product filler places the fastener parts into the plastic thermoforms.
Closing Station– The closing station closes the thermoform lids ensuring all parts are securely sealed in the thermoform.
Unload Station- The unload station transfers the packages from the indexer to the labeler conveyor belt station.
Labeler Station- The bottom and nip conveyors keep the package in place while the product labels are being applied.
Unload Transfer- The packages enter the second unload station, the packages are orientated on the packaging in-feed conveyor.
Carton Infeed- Un-erected cartons are placed in the carton in-feed conveyor. The conveyor automatically indexes to provide the carton erector station with cartons consistently.
Carton Erector- The carton erector picks the carton from the in-feed conveyor. Pneumatic components erect the carton and ensure the tabs are properly inserted.
Robot Pick and Place– The robot picks the packages from the in-feed nest and places them into the erected carton.

DESIGN FEATURES & SPECIFICATIONS

Fanuc Robot Cell
Unload and Reject stations with bins under the machine table.
Class 3 guard enclosure.
Output: 80 PPM.
Stack Light Indicators display the current machine state.
Allen-Bradley 10” PanelView HMI
The machine HMI uses customary pictures & buttons for control overrides. All machine sequences can be
operated in manual mode on the HMI. Current cycle times are displayed on the HMI.

Approximate Combined Machine Dimensions: 30”L x 38’W x 20’H

Filling & Labeling Power Requirements: 480VAC, 3 Phase, 30A

Carton Packaging Requirements: 480VAC, 3 Phase, 30A

Pneumatic Requirements: 80PSI – 5 SCFM