90°rightward distinguishing protector pulse type double valves robot assembly line
1.Basic info
This robot assembly line is designed to assembly 90°rightward distinguishing protector pulse type double valves (model name KP（H）ⅢB-200-3)
90°rightward distinguishing protector pulse type double valves robot assembly line : 7 automatic assembly station, 3 automatic testing station, 4 manual operation table, finished product robot stacking work station and one carrier tool conveyor.
All defected products in the production line generated in the assembly and testing process will be collectively discharged to defected product collecting box set in each unit. The collecting boxes have full-load alarm system to call for manual handling.
10 pieces of 6-axis small load robots are equipped along the conveyor to load and unload materials. 11 pieces of 4-axis SCARA robot arms are equipped to load and unload as well as assembly the parts.
Indexing table: deploying 4 units of 8-station indexing turn table, 2 units of 10-station turn table and 1 unit of 5-station turn table. Automatic centering fixture is designed for the work stations where locating and assembling needs to be realized by automatic centering. For example, work station for the the switch valve.
Cycle time for single piece≤8S. I.E, the interval between each product output is 8S, excluding the time for handling defective products.
The products processed by this line is different in the connector, aluminum cast valve body mounting place, transmission group switch shaft as well as the solenoid valve (single electric control to double electric control). See the 3 models in below picture 1.1. The production line needs to have quick interchanging function to meet the requirements of producing these different products.
2. 90°rightward distinguishing protector pulse type double valves robot assembly line designing basis
product model and actual product
3. 90°rightward distinguishing protector pulse type double valves robot assembly line process analysis
Re-arranged process which contains 32 assembly and testing procedures as follows:
Procedure 1-Auxiliary body assembly: manual assembly on the manual table. The trays stacked with manual assembled auxiliary bodies are transferred to E station manually for the following procedure.
Procedure 2-fine tuning valve core group: manually assembled on manual table. The assembled parts are manually put into the reusable containers (it can be in random order) which will then be transferred to ⑧ vibration disc in A station work position.
Procedure 3- switch valve spring stacking: stacking in the trays manually on the manual table and then the trays will be manually transferred to G station for following procedure.
Procedure 4-Compression spring stacking: manually stacking into trays on the manual table. Then the trays will be manually transferred to F station for following procedure.
Procedure 5-transmision group assembly. Assembly is finished automatically in F station and finished products will be stacked into trays automatically and then the trays will be manually transferred to D station for following procedure.
Procedure 6-assembly valve core group: assembly will be automatically finished in G station. Trays containing the valve core groups will be manually transferred to D station for following procedure.
Procedure 7- valve body conic surface and closer conic surface testing: finished in A station, work position no. 1 & 3.
Procedure 8-valve body group dust blowing-off: finished in A station, work position no. 5.
Procedure 9-closer anointing: in A station, work position no. 6.
Procedure 10-fine tuning valve core group assembly: in A station, work position no. 8 & 9.
Procedure 11-solenoid valve dust blowing-off: in B station, work position no. 2.
Procedure 12-solenoid valve o ring assembly: in B station, work position no.4.
Procedure 13- assembly solenoid valve group: in B station, work position no. 5, 6 & 7.
Procedure 14-Lock process hole screw: in B station, work position no. 8.
Procedure 15- mount outer ring connector: in C station, work position no. 2, 3 and 4.
Procedure 16-mount inner ring connector: in C station, work position no. 5, 6 & 7.
Procedure 17 - place valve core group: in D station, work position 2.
Procedure 18 - fix transmission group: in D station, work position no. 3, 4 & 5.
Procedure 19 - mount fixing plate: in D station, work position no. 7, 8 & 9.
Procedure 20 -fixing plate spray coding: in D station, work position 10.
Procedure 21 -lock auxiliary group: in E station, work position no. 3, 4 & 5.
Procedure 22 -lock side hole screw: in E station, work position no. 6 & 7.
Procedure 23- mount cock: in E station, work position no. 8.
Procedure 24 -synchronized gas testing + solenoid suction: in comprehensive testing table no.1.
Procedure 25 -flow testing & adjusting: in flow testing table.
Procedure 26 - group leaking: in comprehensive testing table no. 2.
Procedure 27 - spot painting: finish spot painting in testing line robot transferring.
Procedure - micro switch: in I station, no. 1 manual work position.
Procedure 29- micro switch testing: in I station no. 2 manual work position.
Procedure 30- Appearance visual inspection: in I station, no.3 work position.
Procedure 31 - packing: after appearance visual inspection,
Product bar code or QR code reading. The codes contains data such as airtight and flow test results for future tracking.
4．Double valves robot assembly line layout and setting
4.1 Double valves robot Assembly line layout
Floor area: 20000mm×6500mm×2500mm (L*W*H). See picture 4.1 for details.
4.2 Double valves robot Assembly line layout Station description
The whole line includes 7 automation assembly stations （A,B,C,D,E,F,G）,3 automatic testing stations （H）， 4 manual operation table, and requires 5 operators.
In A station, 6-axis robots and SCARA conduct and unloading, and the assembly of the shutter and fine tuning valve core groups, as well as the leaking test of the shutter.
In B station, 6-axis robots and SCARA conduct loading and unloading, as well as the assembly of the solenoid valve.
In C station, 6-axis robots and SCARA conduct loading and unloading, and the assembly
In D station, 6-axis robots and SCARA conduct loading and unloading, the assembly of valve core and transmission group. Valve core parts will be assembled in G station, transmission group assembled in F station.
In E station, 6-axis robots and SCARA conduct loading and unloading, assembly of the auxiliary body, side hole screw and cock. The auxiliary body requires manual stacking.
In F station, 6-axis robots and SCARA conduct loading and unloading, and complete the assembly of transmission group. Then the parts will be transported to D station on trays stacked manually.
In G station, SCARA conducts loading and unloading, completes the assembly of valve core group. Finished parts will be manually transported to D station on trays.
In H station, 6-axis robot conducts loading and unloading, and finishes all testing spot painting job.
In I station, loading and unloading will be done manually. The assembly, testing, and visual inspection of micro switch will be done manually. Qualified products will be placed on the tools and automatically grabbed by JINGGONG robot and placed on single layer plastic blister containers. When the containers are filled, manual packing will be prompted. Industry camera is used to determine if the containers are filled. 3 operators required in this station.
2-operator manual stacking position. Job scope: stacking compression spring & switch valve spring, fine adjusting O ring of valve spool cover, assembly of auxiliary body.
The above descriptions are for reference only and subject to actual design.
4.3 Double valves robot Assembly line layout Workstation configuration
substation
Work
position
description
unit
quantity
brand
1.0
A
station. Shutter and fine tuning valve core group assembly and testing station.
set
1
1.1
A
station work position 1 - shutter & switch body loading
Transfer
mechanism
1. AUTO
lifting tray. Change tray manually.
2. High
precision (repetition precision±0.02mm)
4-axis SCARA robot, with high precision centering pneumatic fingers mounted to
the end for grabbing & placing.
SET
set
1
JINGGONG
SCARA
robot
SET
SET
1
EPSON/YAMAHA/OTHERS
Gripper: pneumatic
finger+annex
SET
SET
1
FESTO/SMC＆JINGGONG
Machining
part & annex
SET
SET
1
JINGONG
1.2
A
station work position no.2 - shutter leakage test
Leakage
detector
1. High
precision Differential pressure leak detector deployed for fast product testing
and data transmission
2. It
can realize automatic sealing, testing on/off of gas, product qualifying /
disqualifying.
SET
2
ATEQ/COSMO
Pneumatic
lifting assembly
SET
2
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
2
JINGGONG
1.3
A
station, work position no.3 - shutter & switch body loading
SCARA robot
High
precision (repetition precision±0.02mm)
4-axis SCARA robot, with high precision centering pneumatic fingers mounted to
the end for grabbing & placing.
SET
1
EPSON/YAMAHA/OTHERS
Gripper: pneumatic
finger+annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
1.4
A
station, work position no.4 - shutter and switch body separating
XY
2-axis module group
High
precision high speed 2-axis module group end mounted with high precision
centering pneumatic fingers for grabbing and placing the shutter, to realize the
separating and positioning of the shutter and the valve body
SET
1
FESTO/SMC
Gripper: pneumatic
finger+annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGONG
1.5
A
station work position no. 5 - shutter & switch body dust blowing
off
Pneumatic
lifting assembly
Vacuum
sucks scraps and dust off from the surface of shutter-switch body-mating-plane.
Good absorption performance and will not bring secondary pollution to the
equipment
set
1
FESTO/SMC＆ JINGGONG
Vacuum
scrap suction assembly
SET
1
JINGGONG
Machining
parts & annex
SET
1
JINGGONG
1.6
A
station work position no. 6 - switch body lubrication
multi
spot lubrication system
Automatic
quantified lubrication lubrication oil supply.
SET
1
JINGONG
Pneumatic
lifting assembly
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
1.7
A
station work position no. 7 - assembly of shutter and switch body
XY
2-axis module group
High
precision high speed 2-axis module group end mounted with high precision
centering pneumatic fingers for grabbing and placing the shutter, to realize the
separating and positioning of the shutter and the valve body
SET
1
FESTO/SMC
Gripper: pneumatic
finger+annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
1.8
A
station, work position no. 8 - fine tuning valve core assembly
vibration
disc+linear
feeder
1. Use
vibration disc to feed fine tuning valve core group. Vibration system with noise
reduction measures taken.
2.High
precision high speed 2-axis module group end mounted with high precision
centering pneumatic fingers for grabbing and placing the fine tuning valve core
group, to realize the assembly of fine tuning valve core group.
SET
1
JINGGONG
XY
2-axis module group
SET
1
FESTO/SMC
Gripper: pneumatic
finger+annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
set
1
JINGGONG
1.9
A
station, work position no. 9 - fine tuning valve core group locking
Servo
torque gun + auto feeding system
Servo
screw. Screws using suction method to secure high speed and
stability
SET
1
KILEWS/OTHERS
Machining
parts & annex
SET
1
JINGGONG
1.10
A
station work position no. 10 - shutter direction visual detection
Visual
system
Configured
with million- pixel industry camera + ultra high speed processing system.
Realize high precision dimension measuring and contour recognition.
SET
1
COGNEX/KEYENCE/OTHERS
Machining
parts & annex
SET
1
JINGGONG
1.11
A
station, work position no. 11 - shutter correction & lubrication
Servo
assembly
Shutter
direction acquired by previous procedure. Servo assembly to realize shutter
direction auto correction. Multiple rotate the shutter to evenly apply the
grease between the shutter and valve body.
SET
1
JINGGONG
Pneumatic
lifting assembly
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
1.12
A
station, work position no. 12-unloading
6-axis
robot
Deploying
KAWASAKI or EPSON high precision 6-axis robot (repetition accuracy ±0.02mm）carrying
1 SET self aligning pneumatic fingers and annex, to realize auto
unloading.
SET
1
EPSON/KAWASAKI
Gripper:pneumatic
fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
1.13
A
station, turn table body
Cam
indexer
1. Adopting
high precision cam indexer which has advantages such as high positioning
precision, short start and stop time, long service life, etc.
2. Carrier
tool precision machined & assembled. Centering grabbing when
necessary.
3. Aluminum,
acrylic frame + square steel welded base to achieve both good appearance and
rigidity.
SET
1
SANKYO/TAN
TZU
A
station carrier tool
SET
10
JINGGONG
Machine
rack + outer frame+turntable and mechanical annex
SET
1
JINGGONG
Pneumatic
system
SET
1
FESTO/SMC＆JINGGONG
2.0
B
station. Solenoid and process screw assembly
SET
1
2.1
B
station, work position no.1 - switch body loading
6-axis
robot
Deploying
KAWASAKI or EPSON high precision 6-axis robot (repetition accuracy ±0.02mm）carrying
2 SETS of self aligning pneumatic fingers and annex, to realize auto
unloading.
SET
1
EPSON/KAWASAKI
Gripper:pneumatic
fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
2.2
B
station, work position no.2 - solenoid valve loading
Transferring
mechanism
1. Auto
lifting tray. Manual change tray.
2. Deploying
KAWASAKI or EPSON high precision 4-axis SCARA robot (repetition accuracy ±0.02mm）carrying
high precision self aligning pneumatic fingers and annex, to realize auto
grabbing and placing.
3. Visual
system determines if the solenoid valve is single function or double
function.
4. Vacuum
sucks scraps and dust off. Good absorption performance and will not bring
secondary pollution to the equipment
SET
1
JINGGONG
SCARA
robot
SET
1
EPSON/YAMAHA/OTHERS
Visual
system
SET
1
COGNEX/KEYENCE/OTHERS
Gripper:pneumatic
fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Vacuum
scrap suction assembly
SET
1
JINGGONG
2.3
B
station, work position no. 3 - preserved work position.
2.4
B
station, work position no.4 - mount O ring on solenoid valve
O
ring gripper
Using
O ring gripper from ZIMMER or CHUNK to conduct O ring auto assembly. Simply and
efficient.
SET
1
ZIMMER/CHUNK
Pneumatic
lifting
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
2.5
B
station, work position no. 5 - solenoid groups assembly
Swing
cylinder + pneumatic fingers
Using 180° swing
cylinder + self aligning pneumatic fingers to grab solenoid and finish
assembly.
SET
1
FESTO/SMC
Pneumatic
lifting assembly
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
2.6
B
station, work position no. 6 - auto screwing
Servo
torque gun + auto feeding system
Servo
screwing, by sucking method to secure high speed and stability.
SET
1
KILEWS/OTHERS
Machining
part & annex
SET
1
JINGGONG
2.7
B
station, work position no. 7 - auto screwing
Servo
torque gun + auto feeding system
Servo
screwing, by sucking method to secure high speed and stability.
SET
1
KILEWS/OTHERS
Machining
part & annex
SET
1
JINGGONG
2.8
B
station, work position no. 8 - preserved work position
2.9
B
station, turn table main body
Cam
indexer
1. Adopting
high precision cam indexer which has advantages such as high positioning
precision, short start and stop time, long service life, etc.
2. Carrier
tool precision machined & assembled. Centering grabbing when
necessary.
3. Aluminum
alloy, acrylic frame + square steel welded base to achieve both good appearance
and rigidity.
SET
1
B
station carrier tools
SET
8
JINGGONG
Machine
rack+outer frame+turning disc
SET
1
JINGGONG
Pneumatic
system
SET
1
FESTO/SMC＆JINGGONG
3.0
C
station. Inner and outer ring connector assembly station
SET
1
3.1
C
station,work position no.1 - switch body loading
6-axis
robot
Deploying
KAWASAKI or EPSON high precision 6-axis robot (repetition accuracy ±0.02mm）carrying
2 SETS of self aligning pneumatic fingers and annex, to realize auto
unloading.
SET
1
EPSON
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
3.2
C
station, work position no. 2 - preserved
3.3
C
station, work position no. 3 - inner ring connector loading
Transferring
mechanism
1. Auto
lifting tray. Manual change tray.
2. Deploying
high precision 4-axis robot (repetition accuracy ±0.02mm）carrying
self aligning pneumatic fingers and annex, to realize auto grabbing and
placing.
3. Vacuum
sucks scraps and dust off. Good absorption performance and will not bring
secondary pollution to the equipment
SET
1
JINGGONG
SCARA
robot
SET
1
EPSON/YAMAHA/OTHERS
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Vacuum
scrap suction assembly
SET
1
JINGGONG
3.4
C
station, work position no. 4 - auto applying silica gel
Multi
spot lubrication system
Automatic
and quantified silica gel application
SET
1
JINGGONG
Servo
assembly
SET
1
JINGGONG
Machining
part & annex
SET
1
JINGGONG
3.5
Servo
torque gun + auto feeding system
Servo
screwing, by sucking method to secure high speed and stability.
SET
1
KILEWS/OTHERS
Machining
parts & annex
SET
1
JINGGONG
3.6
C
station, work position no. 6 - outer ring loading
Transferring
mechanism
1.
Auto lifting tray. Manual change tray.
2.
Deploying high precision 4-axis robot (repetition accuracy ±0.02mm）carrying
self aligning pneumatic fingers and annex, to realize auto grabbing and
placing.
3.
Vacuum sucks scraps and dust off. Good absorption performance and will not bring
secondary pollution to the equipment
SET
1
JINGGONG
SCARA
robot
SET
1
EPSON/YAMAHA/OTHERS
Griper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Vacuum
scrap suction assembly
SET
1
JINGGONG
3.7
C
station, work position no. 7 - auto applying silica gel
Multi
spot lubrication system
Automatic
and quantified silica gel application
SET
1
JINGGONG
Servo
assembly
SET
1
JINGGONG
Machining
parts & annex
SET
1
JINGGONG
3.8
C
station, work position no. 8 - auto tightening connector
Servo
torque gun + auto feeding system
Servo
screwing, by sucking method to secure high speed and stability.
SET
1
KILEWS/OTHERS
Machining
parts & annex
SET
1
JINGGONG
3.9
C
station turn table main body
Cam
indexer
1. Adopting
high precision cam indexer which has advantages such as high positioning
precision, short start and stop time, long service life, etc.
2. Carrier
tool precision machined & assembled. Centering grabbing when
necessary.
3. Aluminum
alloy, acrylic frame + square steel welded base to achieve both good appearance
and rigidity.
SET
1
C
station carrier tool
SET
8
JINGGONG
Machine
rack + outer frame+turning disc
SET
1
JINGGONG
Pneumatic
system
SET
1
FESTO/SMC＆JINGGONG
4.0
D
station. Valve core and transmission group assembly station
SET
1
4.1
D
station, work position no. 1 - switch body loading
6-axis
robot
Using
KAWASAKI or EPSON high precision 6-axis robot (repetition accuracy ±0.02mm）carrying
2 sets of self aligning pneumatic fingers and annex, to realize auto grabbing
and placing.
SET
1
EPSON
Gripper:
Pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
4.2
D
station, work position no. 2 - valve core group loading
Transferring
mechanism
1. Auto
lifting tray. Manual change tray.
2. Using
high precision 4-axis robot (repetition accuracy ±0.02mm）carrying
2 sets of self aligning pneumatic fingers and annex, to realize auto grabbing
and placing.
SET
1
JINGGONG
SCARA
robot
SET
1
EPSON/YAMAHA/OTHERS
Gripper:
Pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
4.3
D
station, work position no. 3-transimission group loading
Transferring
mechanism
1. Auto
lifting tray. Manual change tray.
2. Using
high precision 4-axis robot (repetition accuracy ±0.02mm）carrying
2 sets of self aligning pneumatic fingers and annex, to realize auto grabbing
and placing.
SET
1
JINGGONG
SCARA
robot
SET
1
EPSON/YAMAHA/OTHERS
Gripper:
Pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
4.4
D
station, work position no. 4-auto tightening screw
Servo
torque gun+auto feeding system
Servo
screwing, by sucking method to secure high speed and stability.
SET
1
KILEWS/OTHERS
Machining
parts & annex
SET
1
JINGGONG
4.5
D
station, work position no.5 - auto tightening screw
Servo
torque gun+auto feeding system
Servo
screwing, by sucking method to secure high speed and stability.
SET
1
KILEWS/OTHERS
Machining
parts & annex
SET
1
JINGGONG
4.6
D
station, work position no. 6 - transmission group adjusting
Servo
assembly
Adjust
pushing plate position using servo turning mechanism.
SET
1
JINGGONG
Pneumatic
assembly
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
4.7
D
station, work
Servo
torque gun + auto feeding system
Servo
screwing, by sucking method to secure high speed and stability.
SET
1
KILEWS/OTHERS
Machining
parts & annex
SET
1
JINGGONG
4.8
D
station, work position no.8 - auto tightening screw
Servo
torque gun + auto feeding system
Servo
screwing, by sucking method to secure high speed and stability.
SET
1
KILEWS/OTHERS
Machining
parts & annex
SET
1
JINGGONG
4.9
D
station, work position no. 9 - fixing plate loading
Vibration
disc + linear feeder
1. Use
vibration disc to feed fixing plate. Vibration system with noise reduction
measures taken.
2.High
precision high speed 2-axis module group end mounted with high precision
centering pneumatic fingers for grabbing and placing the fixing plate, to
realize the assembly.
SET
1
JINGGONG
XY
two axis module group
SET
1
FESTO/SMC
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
4.10
D
station, work position no. 10 - auto marking
Spray
marking or automation labeling
Auto
spray marking or automation labeling
SET
1
JINGGONG
Machining
parts & annex
SET
1
JINGGONG
4.11
D
station turn table main body
Cam
indexer
1. Adopting
high precision cam indexer which has advantages such as high positioning
precision, short start and stop time, long service life, etc.
2
Carrier tool precision machined & assembled. Self centering grabbing when
necessary.
2. Aluminum
alloy, acrylic frame + square steel welded base to achieve both good appearance
and rigidity.
SET
1
D
station carrier
SET
10
JINGGONG
Machine
rack + outer frame + turning disc
SET
1
JINGGONG
Pneumatic
system
SET
1
FESTO/SMC＆JINGGONG
5.0
E
station. Auxiliary body assembly
SET
1
5.1
E
station, work position no. 1 - switch body loading
6-axis
robot
Using
KAWASAKI or EPSON high precision 6-axis robot (repetition accuracy ±0.02mm）carrying
2 sets of self aligning pneumatic fingers and annex, to realize auto grabbing
and placing.
SET
1
EPSON/KASAWAKI
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
5.2
E
station, work position no. 2 - preserved work position
5.3
E
station, work position no. 3 - auxiliary body manual assembly
5.4
E
station, work position no. 4 - auto screwing
Servo
torque gun + auto feeding system
Servo
screwing, by sucking method to secure high speed and stability.
SET
1
KILEWS/OTHERS
Machining
parts & annex
SET
1
JINGGONG
5.5
E
station, work position no. 5 - auto screwing
Servo
torque gun + auto feeding system
Servo
screwing, by sucking method to secure high speed and stability.
SET
1
KILEWS/OTHERS
Machining
parts & annex
SET
1
JINGGONG
5.6
E
station, work position no. 6 - auto screwing + silica gel applying.
Multi
spot lubrication system
1. Finish
M8 side screw pre-tightening.
2. Automatic
quantified silica gel application.
3. Servo
screwing. M8 screw loading using vibration disc.
SET
1
JINGGONG
Servo
torque gun + auto feeding system
SET
1
KILEWS/OTHERS
Machining
parts & annex
SET
1
JINGGONG
5.7
E
station, work position no. 7 - auto screwing
Servo
torque gun
M8
screw servo tightening.
SET
1
KILEWS/OTHERS
Machining
parts & annex
SET
1
JINGGONG
5.8
E
station, work position no. 8 - cock assembly
Vibration
disc + linear feeder
1. Transfer
cock using vibration disc. Vibration system noise-reduce treated.
2. Visual
system / other sensors to determine cock boss direction. Servo system changes
the cock position, swing cylinder and other cylinder cooperate to finish cock
assembly
SET
1
JINGGONG
X
single axis module group
SET
1
FESTO/SMC
Visual
system
SET
1
COGNEX/KEYENCE/OTHERS
Gripper:
servo motor + swing cylinder + cylinder + guiding cylinder
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
5.9
E
station turn table main body
Cam
indexer
1. Adopting
high precision cam indexer which has advantages such as high positioning
precision, short start and stop time, long service life, etc.
2.
Carrier tool precision machined & assembled. Self centering grabbing when
necessary.
3.
Aluminum alloy, acrylic frame + square steel welded base to achieve both good
appearance and rigidity.
SET
1
E
station carrier
SET
8
JINGGONG
Machine
rack + outer frame + turning disc
SET
1
JINGGONG
Pneumatic
system
SET
1
FESTO/SMC＆JINGGONG
6.0
F
station. Transmission group assembly.
SET
1
6.1
F
station, work position no. 1 - limiting plate loading
Vibration
disc + linear feeder
1. Use
vibration disc to feed limiting plate. Vibration system with noise reduction
measures taken.
2.High
precision high speed 2-axis module group end mounted with high precision
centering pneumatic fingers for grabbing and placing the limiting plate, to
realize the assembly.
SET
1
JINGGONG
XY
two axis module group
SET
1
FESTO/SMC
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
6.2
F
station, work position no.2 - auto lubrication
Multi
spot lubrication system
Automatic
quantified lubricant applying.
SET
1
JINGGONG
Auto
pneumatic assembly
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
6.3
F
station, work position no. 3 - pushing plate loading.
Vibrating
disc + linear feeder
1
Use vibration disc to feed pushing plate. Vibration system with noise reduction.
2.High
precision high speed 2-axis module group end mounted with high precision
centering pneumatic fingers for grabbing and placing the pushing plate, to
realize the assembly.
SET
1
JINGGONG
XY
two axis module group
SET
1
FESTO/SMC
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
6.4
F
station, work position no. 4 - compression spring loading.
Transferring
mechanism
1. Auto
lifting tray. Manual change tray.
2. Using
high precision 4-axis robot (repetition accuracy ±0.02mm）carrying
2 sets of self aligning pneumatic fingers and annex, to realize auto grabbing
and placing.
SET
1
JINGGONG
SCARA
robot
SET
1
EPSON/YAMAHA/OTHERS
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Vacuum
scrap suction assembly.
SET
1
JINGGONG
6.5
F
station, work position no. 5 - bottom plate loading.
Vibrating
disc + linear feeder.
1.
Use vibration disc to feed bottom plate. Vibration system with noise reduction.
2.High
precision high speed 2-axis module group end mounted with high precision
centering pneumatic fingers for grabbing and placing the bottom plate, to
realize the assembly.
SET
1
JINGGONG
XY
two axis module group
SET
1
FESTO/SMC
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex.
SET
1
JINGGONG
6.6
F
station, work position no. 6 - switch shaft loading.
Vibrating
disc + linear feeder.
1.
Use vibration disc to feed switch shaft. Vibration system with noise reduction.
2.High
precision high speed 2-axis module group end mounted with high precision
centering pneumatic fingers for grabbing and placing the switch shaft, to
realize the assembly.
SET
1
JINGGONG
XY
two axis module group
SET
1
FESTO/SMC
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
6.7
F
station, work position no. 7 - E ring assembly
Vibrating
disc + linear feeder
Use
vibrating disc to feed E ring.
SET
1
JINGGONG
E
ring assembly mechanism
SET
1
FESTO/SMC＆JINGGONG
6.8
F
station, work position no. 8 - transmission group unloading
Transferring
mechanism
1. Auto
lifting tray. Manual change tray.
2. Using
high precision 4-axis robot (repetition accuracy ±0.02mm）carrying
2 sets of self aligning pneumatic fingers and annex, to realize auto grabbing
and placing.
SET
1
JINGGONG
SCARA
robot
SET
1
EPSON/YAMAHA/OTHERS
Gripper:
pneumatic fingers + annex.
SET
1
FESTO/SMC＆JINGGONG
6.9
F
station, turn table main body
Cam
indexer
1. Adopting
high precision cam indexer which has advantages such as high positioning
precision, short start and stop time, long service life, etc.
2.
Carrier tool precision machined & assembled. Self centering grabbing when
necessary.
3.
Aluminum alloy, acrylic frame + square steel welded base to achieve both good
appearance and rigidity.
SET
1
三共/潭子
F
station carrier
SET
8
JINGGONG
Machine
rack + outer frame + turning disc
SET
1
JINGGONG
Pneumatic
system
SET
1
FESTO/SMC＆JINGGONG
7.0
G
station. Valve core group assembly.
SET
1
7.1
G
station, work position no. 1 - O ring loading
Vibrating
disc + linear feeder
1. Use
vibration disc to feed O ring. Vibration system with noise reduction.
2.High
precision high speed 2-axis module group end mounted with high precision
centering pneumatic fingers for grabbing and placing the O ring.
SET
1
JINGGONG
XY
two axis module group
SET
1
FESTO/SMC
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
7.2
G
station, work position no. 2 - pressing plate loading
Vibrating
disc + linear feeder
1. Use
vibration disc to feed pressing plate. Vibration system with noise reduction.
2、2.High
precision high speed 2-axis module group end mounted with high precision
centering pneumatic fingers for grabbing and placing the pressing
plate.
SET
1
JINGGONG
XY
two axis module group
SET
1
FESTO/SMC
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
7.3
G
station, work position no. 3 - switch valve compression spring
loading
Transferring
mechanism
1. Auto
lifting tray. Manual change tray.
2. Using
high precision 4-axis robot (repetition accuracy ±0.02mm）carrying
2 sets of self aligning pneumatic fingers and annex, to realize auto grabbing
and placing.
SET
1
JINGGONG
SCARA
robot
SET
1
EPSON/YAMAHA/OTHERS
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
7.4
G
station, work position no. 4 - switch valve loading
Vibrating
disc + linear feeder
1. Use
vibration disc to feed switch valve. Vibration system with noise reduction.
2.High
precision high speed 2-axis module group end mounted with high precision
centering pneumatic fingers for grabbing and placing switch valve.
SET
1
JINGGONG
XY
two axis module group
SET
1
FESTO/SMC
Pneumatic
fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Machining
parts & annex
SET
1
JINGGONG
7.5
G
station, work position no. 3 - valve core group unloading
Transferring
mechanism
1. Auto
lifting tray. Manual change tray.
2. Using
high precision 4-axis robot (repetition accuracy ±0.02mm）carrying
2 sets of self aligning pneumatic fingers and annex, to realize auto grabbing
and placing.
SET
1
JINGGONG
SCARA
robot
SET
1
EPSON/YAMAHA/OTHERS
Gripper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
7.6
G
station turn table main body
Cam
indexer
2. Adopting
high precision cam indexer which has advantages such as high positioning
precision, short start and stop time, long service life, etc.
2.
Carrier tool precision machined & assembled. Self centering grabbing when
necessary.
2、3.
Aluminum alloy, acrylic frame + square steel welded base to achieve both good
appearance and rigidity.
SET
1
G
station carrier
SET
5
JINGGONG
Machine
rack + outer frame + turning disc
SET
1
JINGGONG
气动系统
Pneumatic
system
SET
1
FESTO/SMC＆JINGGONG
8.0
H
station. Auto testing.
SET
1
8.1
General
testing table one
Testing
tools
1. Using
KAWASAKI or EPSON high precision 6-axis robot (repetition accuracy ±0.02mm）carrying
2 sets of self aligning pneumatic fingers and annex, to realize auto grabbing
and placing.
2. Establish
flow test loop and finish synchronized gas testing procedure.
3. Solenoid
valve pull-in test is done using a resistance meter.
4. The
testing table uses square steel welded + aluminum profile. Beautiful and
strong.
5. Independent
electrical control system. Signal interact with bus.
SET
4
JINGGONG
Testing
table frame
SET
1
JINGGONG
IPC (Industrial
Personal Computer)
SET
1
LENOVO
Flow
meter
SET
8
ALICAT/FESTO/OTHERS
6-axis
robot
SET
1
EPSON/KAWASAKI
Gripper:
pneumatic fingers +annex
SET
1
FESTO/SMC＆JINGGONG
Pneumatic
annex
SET
1
FESTO/SMC
Electric
control system
SET
1
西门子＆施耐德
SIEMONS
& SCHNIEDER
8.2
Flow
adjustment
Testing
tools
1. Using
KAWASAKI or EPSON high precision 6-axis robot (repetition accuracy ±0.02mm）carrying
2 sets of self aligning pneumatic fingers and annex, to realize auto grabbing
and placing.
2. Establish
flow test loop. Use electrical proportional valve to make sure input gas
pressure stable. The pressure value is read at a fixed time and fed back to the
PLC for judgment and adjustment.
3. The
testing table uses square steel welded + aluminum profile. Beautiful and
strong.
2、Independent
electrical control system. Signal interact with bus.
SET
4
JINGGONG
Testing
table frame
SET
1
JINGGONG
Flow
adjustment system
SET
4
JINGGONG
6-axis
robot
SET
1
EPSON/KAWASAKI
Griper:
pneumatic fingers + annex
SET
1
FESTO/SMC＆JINGGONG
Pneumatic
annex
SET
1
FESTO/SMC
Electric
control system
SET
1
Siemens & Schneider
8.3
General
testing table two
Testing
tools
1. Using
KAWASAKI or EPSON high precision 6-axis robot (repetition accuracy ±0.02mm）carrying
2 sets of self aligning pneumatic fingers and annex, to realize auto grabbing
and placing.
2. Establish
air tightness test loop and finish general air tightness test.
3. Testing
table uses square steel welded + aluminum profile. Beautiful and
strong.
4. Independent
electrical control system. Signal interact with bus.
SET
6
JINGGONG
Testing
table frame
SET
1
JINGGONG
Leakage
detector
SET
6
ATEQ/COSMO
6-axis
robot
SET
2
EPSON/KAWASAKI
Gripper:
pneumatic fingers + annex
SET
2
FESTO/SMC＆JINGGONG
Pneumatic
annex
SET
1
FESTO/SMC
Electric
control system
SET
1
SIEMENS
& SCHNEIDER
9.0
I
station. Micro switch assembly & testing station
SET
1
9.1
Micro
switch assembly
Pneumatic
tools + operation table
Manually
mount micro switch with pneumatic tools
SET
1
JINGGONG
9.2
Micro
switch test
Resistance
meter +
operation table
Manually
place the products which are mounted with micro switches on the testing work
position for automatic testing and judging.
SET
1
JINGGONG
9.3
Visual
inspection table
Operation
table
Manual
visual inspection
SET
1
JINGGONG
9.4
Automatic
single layer stacking
Robot
system
1. 6-axis
robot grab the product and stack it in single layer plastic blister container.
2. Visual
system detects if there’s
missing product.
3. When
the containers are filled, manual packing will be prompted by signal.
SET
1
JINGGONG
Visual
system
SET
1
COGNEX/KEYENCE/OTHERS
annex
SET
1
JINGGONG
10.0
F
station. Transferring line module.
SET
1
10.1
Transferring
line module.
Transferring
line.
1. Belt
conveyor, transferring carrier.
2. Carrier
is transferred to each work position and stopped by the stopping mechanism and
then robot will pick up the carrier.
SET
1
JINGGONG
Stopping
mechanism
SET
10
JINGGONG
carrier
SET
30
JINGGONG
Carrier
transferring system
SET
2
JINGGONG
Electrial Control System
SET
1
11
PLC
general control system
S7-1500
SET
1
SIEMENS&JINGGONG
Power
& storage card
SET
SIEMENS
Input
module
SET
SIEMENS
Output
module
SET
SIEMENS
Communication
module
SET
SIEMENS
Touch
screen
SET
SIEMENS
Light
curtain, door sensor, etc.
SET
AB/OMRON/OTHERS
Electric
control cabinet
SET
好夫满
Low
electrical apparatus and cable accessories
SET
JINGGONG
5. Double valves robot Assembly line layout main device introduction
5.1 6-axis robot system
In this project, KAWASAKI 6-axis robot is used, with E74 controller. Robot load 5kg, max motion radius 705mm, repetition accuracy ±0.02mm, as in the following pictures
|
Table 5.1 Kawasaki 6-axis robot Performance parameter |
||
|
load |
5KG |
|
|
Number of motion axes |
6 |
|
|
Repetition accuracy |
±0.02mm |
|
|
regulator |
E74 |
|
|
Dead weight |
34KG |
|
|
Motion parameter of each axis |
Motion range |
Motion speed |
|
Axis 1 |
+/-180° |
360°/s |
|
Axis 2 |
+135°/ -80° |
360°/s |
|
Axis 3 |
+118°/ -172° |
410°/s |
|
Axis 4 |
+/-360° |
460°/s |
|
Axis 5 |
+/-145° |
460°/s |
|
Axis 6 |
+/-360° |
740°/s |
|
Max motion radius |
705mm |
|
5.2 SCARA robot system
In this project, EPSON SCARA robot is used, with RC90 controller. Robot max load 6kg, max motion radius 600mm, repetition accuracy ±0.02mm, as in the following pictures.
|
Table 5.2 EPSON SCARA robot performance parameter |
||
|
load |
6KG |
|
|
Number of motion axes |
4 |
|
|
Repetition accuracy |
±0.02mm |
|
|
controller |
RC90 |
|
|
Dead weight |
17KG |
|
|
Motion parameter of each axis |
Motion range |
Motion speed |
|
Axis 1 |
+/-132° |
6800mm/s |
|
Axis 2 |
+/-150° |
|
|
Axis 3 |
/ |
1100mm/s |
|
Axis 4 |
/ |
2000deg/s |
|
Max motion radius |
600mm
|
|
The operation is turn table type using SANKYO AD series cam indexer. Cam indexer repetition accuracy is 30 arc seconds. SEW motor with SEW inverter and brake. Turning table turning direction can be switched between clockwise and anti-clockwise. Schematic, accuracy and load parameter as in the following pictures.
AD series cam indexer turn table schematic
5.4 visual system
COGNEX industry camera is adopted in this project to detect the state of the shutter. Correcting device corrects the shutter position based on the visual inspection results. Visual work position and visual system parameters are in the following pictures.
visual inspection work position COGNEX industry camera
COGNEX industry camera application
5.5 auto screwing system
Auto screwing system is used to screw automatically. This system can realize functions including automatic feeding screws and automatic tightening screws of multiple specifications. See following pictures
automatic screwing work position auto screwing system application
5.6 robot assembly line testing system
Testing system includes synchronized testing gas detection + solenoid valve pull-in test, flow testing & adjusting, and combined leakage detection.
Synchronized testing gas detection + solenoid valve pull-in test: Pressure transmitter reads exit pressure of inner and outer ring, resistance meter reads pull-in current value. These values are displayed on the screen of the IPC after communicating with PLC.
Flow testing and adjusting: electrical proportional valve tests the flow. The exit flow value will be fed to PLC inside which these values will be processed and then the result will be fed to servo motor which will then work to adjust the flow to required range. If the flow value is too big, or the adjusting fails to get it into the required range in a certain amount of time, the flow test is considered failed.
Combined leakage test: use ATEQ F620 leakage detector. Pressure is electrically adjusted.
testing work position
5.7 robot assembly line Gas system
6 bar standard compressed air is used here. The air flow is subject to the fixture design. Gas fluctuation range ±10%, filtration accuracy 5-40um. Equipped with soft starting module, pressure relief valve, flow & pressure monitor module.
5.8 robot assembly line electric control system
The electric control system uses PLC to connects robots, indexer system through bus line (Optical fiber) and forms a complete system and connects the robot station touch screen through MPI bus line. Robot and indexer system are controlled by PLC.
The human-machine interface uses a 10-inch Siemens color touch screen. The touch-screen operation panel is used to display the operating status and fault type of each device in the workstation. The system operation and status indication are simple and intuitive, and the function expansion is flexible.
There are two operation modes: manual mode and automatic mode. In the automatic mode, the operator only needs to load the work piece and press the start button on the operation table. After work piece fixed on the fixture, the work station will automatically complete the whole series of coherent actions including robot welding and fixture release. In the manual mode, single step action of each fixture can be realized throgh touch screen.
Equipment and working parameter can be set in through the touch screen. The operation is protected by multiple levels of passwords. Unauthorized personnel cannot modify or change the parameters. Passwords entry validity is 2 minutes.
Communication interface can communicate directly with the computer to transfer program files related to the parts.
There are status display and current position display functions.
There are auto diagnosis and remote diagnosis function which make it convenient for quick repair response when malfunction occurs.
There are an fixture online control input interface through which the automated fixtures can be controlled.
ZHEJIANG JINGGONG ROBOTICS & INTELLIGENT EQUIPMENT CO.,LTD is a high-tech enterprise, with robot technology as the core, to provide digital intelligent integration solutions.Parent company ZHEJIANG JINGGONG SCIENCE & TECHNOLOGY CO., LTD. registered capital of 450 million, it went public at Shenzhen Stock Exchange in 2004, the stock code is 002006.
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