| Customization: | Available |
|---|---|
| After-sales Service: | Available |
| Warranty: | Available |
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The equipment, apart from manually loading the valve body and valve cap, utilizes an 8-station rotary table, a vibrating feeder, and multiple sets of robotic arms to automatically perform the assembly process in sequence. It synchronously completes the following steps: fitting plastic gaskets on the valve body and valve cap, applying adhesive to the valve cap, flipping the valve cap, tightening the valve cap, and finally, removing the finished product. This enables all components to be assembled into the final product in one step, reducing labor costs and improving production efficiency.
| 1 | Scope of application | Exhaust Valve |
| 2 | Cycle time | 6500 Pcs/8 hours |
| 3 | Servo motor power | 0.4KW |
| 4 | Gearbox gear ratio | 5:1 |
| 5 | Compressed air | >4kg.cm2 |
| 6 | Power supply | AC220V |
| 1 | Pneumatic Cylinder | AIRTAC | Multiple specifications |
| 2 | Solenoid Valve | AIRTAC | Multiple options with customization |
| 3 | Splitter | China branded | DT110 |
| 4 | PLC - Programmable Logic Controller | China branded | Multi-functional customization |
| 5 | Gearbox (reducer) | SAINADE | 60-5 |
| 6 | Servo motor | China branded | Servo 60 |
| 7 | Touch screen | XINJE | TG765-WG |
Rotary transfer machines offer several advantages in the manufacturing industry due to their unique design and capabilities. Here are some of the key advantages of using rotary transfer machines:
High production rates: Rotary transfer machines are designed to handle multiple workstations simultaneously, allowing for the simultaneous processing of multiple parts. This results in high production rates and increased throughput, making them ideal for high-volume manufacturing.
Precision and accuracy: These machines are built with high-quality components and advanced control systems, ensuring precise and accurate machining. The rotary motion allows for consistent and repeatable positioning, leading to tight tolerances and improved part quality.
Reduced setup time: Rotary transfer machines are designed for quick changeovers between different production runs. Once the initial setup is complete, subsequent changeovers are relatively fast, reducing downtime and increasing overall efficiency.
Flexibility: Despite their high-volume capabilities, rotary transfer machines can handle a wide range of part sizes and geometries. With the ability to accommodate multiple tools and operations, they offer versatility in manufacturing different components.
Cost-effectiveness: While rotary transfer machines require a significant initial investment, their high production rates and efficiency can lead to substantial cost savings in the long run. The reduced labor costs and increased output contribute to a lower cost per part.
Operator safety: Rotary transfer machines are often fully enclosed, protecting operators from potential hazards associated with the machining process. This enclosure also helps in containing chips and coolant, making the working environment cleaner and safer.
Minimized cycle times: Due to their simultaneous processing of multiple parts and operations, rotary transfer machines can significantly reduce cycle times, enhancing overall productivity.
Automation integration: Rotary transfer machines can be easily integrated into automated production lines, further enhancing their efficiency and reducing the need for manual intervention. This enables lights-out manufacturing, where the machines can operate autonomously for extended periods.
Space-efficient: Rotary transfer machines are designed to occupy a relatively small footprint compared to traditional manufacturing setups that involve multiple standalone machines. This space-saving design is beneficial for optimizing floor space in the factory.
Consistency and reliability: Once properly set up, rotary transfer machines tend to operate consistently and reliably, minimizing variations in part quality and reducing the risk of defects or errors.
Feeding: The raw materials, components, or parts required for the assembly process are fed into the machine. This can be done manually or using automated feeding mechanisms, such as conveyor belts or robotic arms.
Orientation and Positioning: The machine may need to orient or position the components correctly before assembly. This step ensures that each part is in the right position and alignment for the subsequent assembly steps.
Assembly Process: The machine performs the actual assembly process, which could involve tasks like joining components, inserting fasteners, soldering, welding, gluing, or other specific assembly operations.
Verification and Quality Control: Many assembly machines are equipped with sensors and inspection systems to verify that each assembly step is completed correctly. This helps ensure the quality and accuracy of the final product.
Transfer and Conveyance: Once the assembly is complete, the finished products or sub-assemblies may be transferred to the next stage of production using conveyor belts, robotic arms, or other transfer mechanisms.
Replenishment: If the assembly machine is part of a continuous production line, it may need to be replenished with new raw materials or components to maintain an uninterrupted manufacturing process.
Error Handling: If the machine detects any defects or errors during the assembly process, it may trigger error-handling mechanisms, such as stopping production, signaling an alert, or initiating rework.
Human Interaction: In some cases, human operators may be involved in overseeing the assembly process, handling exceptions, or performing specific tasks that require manual intervention.
Data Collection and Analysis: Assembly machines with advanced automation capabilities may collect data on production metrics, quality parameters, and machine performance. This data can be used for analysis, process optimization, and predictive maintenance.
Cleaning and Maintenance: Regular cleaning and maintenance are essential to ensure the proper functioning of the assembly machine and to extend its lifespan.
OEM/ODM
Our company has our own unique team of designers, for different types from OEM &ODM customer's needs!
We are with more than 10 years' experience in OEM/ODM service, including particular product function development, particular package, sample developing etc.
R&D
Our company has set up the R&D software department and R&D machinery department.
We have a strong R & D team from Germany, Japan and China.
We could do the design new machine for you with a unique software and case of your base at your special request.
Online technical support is available through social software for most of our products, such as CNC lathes. Another way is to pre-install modules for remote monitoring technical support in the equipment, so that remote technical support can be provided via the Internet in the event of a failure, such as rotary transfer machine. For most of our machines we send spare parts for some of the easily breakable parts with the machine.
How to maintain an assembly machine
Maintaining an assembly machine is crucial to ensure its optimal performance, prevent breakdowns, and extend its lifespan. Regular maintenance can also reduce downtime and production losses. Here are some essential tips on how to maintain an assembly machine:
Follow the Manufacturer's Guidelines: Always adhere to the maintenance instructions and schedules provided by the machine manufacturer. They know their equipment best and can recommend the specific maintenance tasks and intervals required for optimal performance.
Create a Maintenance Schedule: Develop a maintenance schedule that includes regular inspections, cleaning, and servicing. The frequency of maintenance tasks will depend on the machine's usage and the manufacturer's recommendations.
Keep the Machine Clean: Regularly clean the machine to remove dust, debris, and any accumulated residues. Pay special attention to moving parts, sensors, and electronic components.
Lubrication: Proper lubrication is essential for smooth operation and to prevent wear and tear on moving parts. Follow the recommended lubrication schedule and use the correct lubricants specified by the manufacturer.
Inspection of Wear Parts: Regularly inspect wear parts such as belts, chains, gears, and bearings for signs of wear. Replace any damaged or worn-out components promptly to avoid further damage to the machine.
Tighten Loose Fasteners: Vibrations during operation can cause fasteners to become loose over time. Regularly check and tighten all nuts, bolts, and screws to ensure stability and safety.
Check Safety Features: Verify that all safety features and emergency stop mechanisms are working correctly. Safety should be a top priority to protect both the machine operators and the equipment itself.
Monitor Sensors and Controls: Check and calibrate sensors and controls regularly to ensure accurate readings and proper functioning.
Keep Records: Maintain a comprehensive record of all maintenance activities, including dates of service, replacement parts, and any issues encountered. This record can be helpful for tracking the machine's performance and identifying patterns or recurring problems.
Train Operators: Ensure that machine operators are well-trained in the proper operation and basic maintenance of the assembly machine. They should be aware of warning signs, safety protocols, and know how to perform routine checks.
Address Issues Promptly: If any issues or abnormalities are detected during regular inspections or while operating the machine, address them promptly. Ignoring small problems can lead to more significant breakdowns and costly repairs.
Schedule Professional Maintenance: While regular in-house maintenance is essential, also consider scheduling periodic professional maintenance or service visits from the manufacturer or authorized technicians.
By implementing these maintenance practices, you can maximize the efficiency and reliability of your assembly machine, leading to smoother production processes and higher-quality output.
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