Robot and Conveyor System for Ejection Seat Manufacturer
Banelec were contacted by this customer to design, construct, create software for, install and commission an entire machining cell, this was our customers first ever robot cell having performed manual tasks for many decades. The results have been overwhelming and our customer is hoping to order the next cells in the near future.
Міндет
We were approached by the customer to create a system for a prestigious aerospace ejector seat manufacturer, which would allow the continuous manufacture of ejector seat shafts without the need for continuous human intervention throughout the process. Banelec was instructed to design both the electrical and mechanical elements of this project, as well as the software design.
Бұл біз құрдық
Our design involved a multi process operation; to begin, a blank is fed into CNC machine # 1 for its first procedure, this is then unloaded by our robot and the component placed upon the lower tier of our bespoke 2-teir conveyor, on the buffer section.
Meanwhile CNC machine # 2 has now completed the second and final procedure, the robot then removes this component and delivers it to the upper tier of the conveyor on the delivery section. While waiting for the first procedure to complete our robot once again collects the first component and loads it into CNC machine # 2 and the process repeats itself for the entire shift.
The customer provided us with samples of the ejector seat shaft and told us their preferred production time. This allowed us as a team to get a feel for the product and what was required from the robot and conveyor in terms of speed and precision whilst considering the gripper design for grabbing and manipulating the product.
Design
Our customer’s Initial thought was that two robot cells would be required, basically double the expense and double the space required. However, by using our robot modelling and 3D CAD software packages we found we were able to perform the process within a single cell using a single robot but with a unique bespoke 2-tier conveyor system.
A site survey was performed to measure the space in which the system was to be introduced and to assess the safety requirements for the area, allowing us to build a concept using safety fencing, plan the length of conveyor taking into account the number of parts being placed on to it per hour and assess the allowed pivot room of the robot to ensure it was capable of the manoeuvres required to carry out its function.
For this project we were involved with every aspect of the design process, even the design of the conveyor itself. Our mechanical designer developed the concept and used our in-house design software to provide in depth drawings of what was required to produce the components for manufacture. The framework, brackets, plates and track were all produced by trusted companies in our supply chain and then the conveyor was constructed by our mechanical engineers. It was designed so well that no welded was required on any of the conveyor system.
Орнату
Our own team completed the installation on site, fitting every element of the system, ensuring everything was fixed down safely in the correct position as per the floor plan and design. We electrically connected the system, ensuring all cables were terminated as per our schematics, produced with AutoCAD Electrical. Once the system was fully installed and connected, our PLC engineer ensured the software functioned as intended, that the robot and conveyor functioned together as designed, and that the customer was satisfied with the system.
Нәтижесі
Upon completion of the project, following installation and commissioning, our Banelec Software designer and supporting engineer visited the site to conduct training with the facilities staff to ensure all personnel on site were competent at using the installed equipment. As part of the complete package the designer also created a manual for the machine so that engineers using the machine can have information readily at hand whenever in doubt.
The successful development of this custom machining cell provides the customer with increased productivity, reduced labour costs and enhanced safety. This project has seen Banelec explore their mechanical design capabilities and has opened the way for us to work on more complete turn-key projects like this in the future.