Robot Packing Application

System Description:

This new robot based automation uses DENSO robots to load and unload components. A storage hopper trickle feeds plastic cases on demand into a vibratory bowl feeder. After being sorted in the bowl, into one of two orientations, the cases are delivered onto an infeed conveyor. Here the first DENSO robots picks up a case, to allow sensors to check its orientation and condition. Components failing this specification check are rejected. The robot then presents the good case to the next stage of the assembly operation.

Dispensers are also fed from a vibratory storage hopper and bowl into correct orientation for insertion into the cases. Blades, from the blade-grinding machine, are delivered in trays and automatically fed by conveyor into an upload station where they are prepared for loading into the cases. At the same time a strip of steel feeds into a press where it is cut to form the spring, which is inserted in the case behind the blades. 

The case is then closed and checks are made to ensure the spring and blades are correctly inserted. A final robot palletises the cases, six layers deep with 28 cases to a layer, into a tote bin which is orientated correctly for final packaging.

System Features:

The new robotic process at this company has significantly reduced handling operations and improved productivity in knife blade dispenser packaging operations. AA Robotics, and one of it's System Integrators, Aylesbury Automation Limited, has designed and installed automated packaging technology using DENSO robots to maximise the benefits of ‘lean manufacturing’, reduced stock holding and shortening delivery lead times of blade dispensers.

The customer manufactures and markets tools, hardware and speciality products worldwide for both the home improvement market and industrial and professional use. Founded in 1843 in Connecticut USA to manufacture door bolts and other wrought iron products, today's demand for replacement blades for the ‘Stanley Knife’ is growing and it was this increased demand which led to the requirements for improved automation. 

“Aylesbury Automation designers brought a great deal of experience in automated assembly and robotic packaging to the job, and they have succeeded in providing a solution which is extremely efficient and cost-effective,” (Howard Walker – Senior Engineer).

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