MU 7 Mak Fu Shun Kong Yau Choi Lee Man Kit Poon San On Zen YKK Project: Automatic adhesive machine.
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Transcript of MU 7 Mak Fu Shun Kong Yau Choi Lee Man Kit Poon San On Zen YKK Project: Automatic adhesive machine.
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MU 7 MU 7 Mak Fu ShunMak Fu Shun
Kong Yau ChoiKong Yau ChoiLee Man KitLee Man Kit
Poon San On ZenPoon San On Zen
YKK Project:
Automatic adhesive machine
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IntroductionIntroduction
YKK Hong Kong Limited YKK Hong Kong Limited established in 1966.established in 1966.
As a subsidiary of YKK As a subsidiary of YKK Corporation. Corporation.
One of the biggest One of the biggest corporation in producing and corporation in producing and selling zippers.selling zippers.
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IntroductionIntroduction Co-operate with YKK Co. to design an extended Co-operate with YKK Co. to design an extended
automatic adhesive machine.automatic adhesive machine.
Existed Automatic adhesive machineExisted Automatic adhesive machine
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IntroductionIntroductionYKK Co. now can only stick the tape onto the middle region of the box. (Easier task)
Our job is to design a machine to stick the other two sides.
(More complicated)
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At this region, At this region, here are the 2 here are the 2
adhesive adhesive machines machines
given from given from YKK, which YKK, which
are not shown are not shown to reduce to reduce
complicated complicated drawing.drawing.
The cylinder with a plate to push the box forward.
The result are like above, only half is attached!
Initial Design 1
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Each set has 2 cylinders, first the horizontal ones extends to touch the box.
Initial Design 2
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Initial design 2Initial design 2
VincentVincent
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Once the box press the senor, cylinder will push the box to the second conveyer. Therefore, the box can change the direction.
Sensor
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Then the box will pass through the sticking machine.
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Initial Design 3Initial Design 3
EddieEddie
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Initial design 3Initial design 3
brush
smoother
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Initial design 4Initial design 4
By Jason
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Initial design 4Initial design 4
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Intermediate Design
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Step 1 :
To push the box into conveyor
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Step 2 :
Stick adhesive paper on the box
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Step 3 :
Rotational cylinders press the adhesive paper firmly
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Final Step :
Cylinders press adhesive paper firmly
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Different Size of boxes
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Final Design
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New Design
Old Design
The different between new design and old design
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Old Design
New Design
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Working Mechanism
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Main support : Hold the upper support and adjust the height for different boxes size
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Parts : Cylinder
Linear Bearing
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Upper Support : Hold the all the main part of adhesive machine and adjust the wide
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Cylinder and Linear bearings
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Hold all the main parts
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BOMBOM Two Adhesive machinesTwo Adhesive machines
9 Cylinders9 Cylinders
6 linear bearings6 linear bearings
22 Sensors22 Sensors
1 PLC model1 PLC model
1 Touch Panel1 Touch Panel
Long/Uncut Profiles, Cables… Long/Uncut Profiles, Cables…
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Planning of worksPlanning of works1.1. Profiles cutting & Surface finishing ~1.5 weeks (Profiles cutting & Surface finishing ~1.5 weeks (due to change of desigdue to change of desig
nn))2.2. Holes drilling ~5 daysHoles drilling ~5 days3.3. Construction of frames ~2.5 daysConstruction of frames ~2.5 days4.4. Mounting parts for cylinders installed on frame ~2 weeksMounting parts for cylinders installed on frame ~2 weeks
5.5. PLC & Touch Panel Programming learning ~ 1.5 days PLC & Touch Panel Programming learning ~ 1.5 days 6.6. Simens PLC Programming Simulation and testing ~ 3 daysSimens PLC Programming Simulation and testing ~ 3 days7.7. PLC programming drafting ~1.5 daysPLC programming drafting ~1.5 days8.8. PLC programming design ~3 daysPLC programming design ~3 days9.9. Touch Panel programming design ~2.5 daysTouch Panel programming design ~2.5 days10.10. Testing & Debugging on working condition ofTesting & Debugging on working condition of
touch Panel connecting with PLC. ~2 days touch Panel connecting with PLC. ~2 days11.11. Installation & connection of PLC, Touch PanelInstallation & connection of PLC, Touch Panel
and solenoid valve using cables ~3 daysand solenoid valve using cables ~3 days
(PLC & TP finished by 24 June.) (PLC & TP finished by 24 June.)12.12. Website making ~1.5 weeks, continuouslyWebsite making ~1.5 weeks, continuously13.13. Modification on the design ~1 weekModification on the design ~1 week14.14. Whole machine testing and debugging ~2 daysWhole machine testing and debugging ~2 days
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MachiningMachining
MachiningMachining
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Machining WorkshopMachining Workshop
Milling MachineMilling Machine- holes drilling- holes drilling- surface finishing- surface finishing
Sawing MachineSawing Machine-cutting Profiles-cutting Profiles
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Milling MachineMilling Machine
IIncrease the smoothnencrease the smoothness of the surfacess of the surface
Rotating speedRotating speed Cooling liquidCooling liquid
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Milling MachineMilling Machine
Drilling holesDrilling holes
Milling SurfacesMilling Surfaces
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Milling MachineMilling Machine Drilling holesDrilling holes
- Center Drill- Center Drill- corresponding dia - corresponding dia DrillDrill, E.g. 6 mm dia Drill , E.g. 6 mm dia Drill (different sizes)(different sizes)- 26-- 26-mm dia Drillmm dia Drill- Boring tool- Boring tool
CautionsCautions
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Milling MachineMilling Machine Milling SurfacesMilling Surfaces
- Milling Cutter - Milling Cutter (different sizes)(different sizes)
CautionsCautionsdo not mill deeplydo not mill deeply& too fast& too fast
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Milling MachineMilling Machine ProductsProducts
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PartsParts
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Sawing MachineSawing Machine CautionsCautions
- adding cooling liquid- adding cooling liquid
IIncrease the smoothness of the surfacencrease the smoothness of the surface- cutting error- cutting error shorter shortermilling surface milling surface
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NCM WorkshopNCM Workshop
EElectro-lectro-DD ischarge ischarge MMachine achine (EDM)(EDM)- Wire Cut- Wire Cut
(the shaft is too (the shaft is too hard)hard)
CautionsCautions- - Flammable Liquid Flammable Liquid
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Difficulties in MachiningDifficulties in Machining
High PrecisionHigh Precision-squareness-squareness-same length-same length
Some holes are too big to drillSome holes are too big to drill Linear bearing shaftLinear bearing shaft
- too hard (strong steel)- too hard (strong steel) Thread not matchedThread not matched - Straight Adaptor does not fit - Straight Adaptor does not fit
cylinder provided by YKKcylinder provided by YKK
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System ControlSystem Control
Pneumatics Pneumatics /Cylinders /Cylinders
Connect to output devices
Both Input & OutputSensor
Connect to input devices
Connect to Touch Panel
Solenoid Valves
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Why use PLC?Why use PLC?• Cost effective.
High stability and flexibility.
•Can work under adverse environment.
•Easy programming.
•Plenty input and output addresses, moreover extendable.
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Input & Output addressesInput & Output addresses24 Input Addresses (All used)
000: Touch Sensor
001: Retraction sensor of Long Cylinder.
002:Extension sensor of Long Cylinder.
003-010: Built-in sensors of Cylinders.
011: Big Box button.
100-107: Built-in sensors of Cylinders.
108-109:External Photoelectric Sensor.
110: Start Button
111:Reset Button
16 Output Addresses: (10 used)
1000-1100:Cylinders
1101: Blocking unit
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Input/Output Table for PLCInput/Output Table for PLC
Step Pre-condition Practical Output
1 110(start) pressed 000-Touch sensor (TS) is turned on and ready for use.
2 000 is triggered by box
1000(LC) is set, 1001-1005 are reset.
3 108 (RS) senses from 0 to 1 when box passes in
1001,1002 are set (rotate 180)
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PLC Programming
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Why use Touch Panel?Why use Touch Panel?
Can emulate buttons & switches Can emulate buttons & switches easily.easily.
Reduce complication.Reduce complication.
Can emulate lights.Can emulate lights. Check output status.Check output status.
Shows the input & output status.Shows the input & output status. Check the operating process.Check the operating process.
Easy Programming.Easy Programming. High efficiency.High efficiency.
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Touch Panel ProgrammingTouch Panel Programming
Press Start button sensors triggers, machine works on itself.
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Status of Sensors & CylindersStatus of Sensors & Cylinders
LC: long cylinderRC: rotational cylinderBC: Brush cylinder
boxes counter: use Sensor to sense the box, and add 1 each time.
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TestingTesting
Test on PLC Program
Use Dip-Switch to emulate the sensors and buttons.
Test on Touch Panel with PLC
Test if PLC reacts exactly to the commands of Touch Panels.
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TestingTesting
Test on built-in Sensor with PLC
The retraction sensor reacts and switch on the input 000 of PLC. Both lights’ ON.
Test on Solenoid Valve to control the gas flow & direction of cylinders.
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Video ClipsVideo Clips
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ConclusionConclusion We have learntWe have learnt- How to apply our knowledge & study How to apply our knowledge & study
on practical tasks.on practical tasks.
- How to communicate and co-operate How to communicate and co-operate with companies.with companies.
- Dealt with variable difficulties.Dealt with variable difficulties.
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ConclusionConclusion
- Better understanding on IC workshops.Better understanding on IC workshops.
- How to put ideas into reality.How to put ideas into reality.
- Importance on effective planning of Importance on effective planning of work.work.
-Many mechanical knowledge, -Many mechanical knowledge, technological products, and technological products, and programming.programming.
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The endThe end