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Kong Yau ChoiKong Yau ChoiLee Man KitLee Man Kit

Poon San On ZenPoon San On Zen

YKK Project:

Automatic adhesive machine

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.

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

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)

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

Each set has 2 cylinders, first the horizontal ones extends to touch the box.

Initial Design 2

Initial design 2Initial design 2

VincentVincent

Once the box press the senor, cylinder will push the box to the second conveyer. Therefore, the box can change the direction.

Sensor

Then the box will pass through the sticking machine.

Initial Design 3Initial Design 3

EddieEddie

Initial design 3Initial design 3

brush

smoother

Initial design 4Initial design 4

By Jason

Initial design 4Initial design 4

Intermediate Design

Step 1 :

To push the box into conveyor

Step 2 :

Stick adhesive paper on the box

Step 3 :

Rotational cylinders press the adhesive paper firmly

Final Step :

Cylinders press adhesive paper firmly

Different Size of boxes

Final Design

New Design

Old Design

The different between new design and old design

Old Design

New Design

Working Mechanism

Main support : Hold the upper support and adjust the height for different boxes size

Parts : Cylinder

Linear Bearing

Upper Support : Hold the all the main part of adhesive machine and adjust the wide

Cylinder and Linear bearings

Hold all the main parts

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…

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

MachiningMachining

MachiningMachining

Machining WorkshopMachining Workshop

Milling MachineMilling Machine- holes drilling- holes drilling- surface finishing- surface finishing

Sawing MachineSawing Machine-cutting Profiles-cutting Profiles

Milling MachineMilling Machine

IIncrease the smoothnencrease the smoothness of the surfacess of the surface

Rotating speedRotating speed Cooling liquidCooling liquid

Milling MachineMilling Machine

Drilling holesDrilling holes

Milling SurfacesMilling Surfaces

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

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

Milling MachineMilling Machine ProductsProducts

PartsParts

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

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

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

System ControlSystem Control

Pneumatics Pneumatics /Cylinders /Cylinders

Connect to output devices

Both Input & OutputSensor

Connect to input devices

Connect to Touch Panel

Solenoid Valves

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.

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

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)

PLC Programming

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.

Touch Panel ProgrammingTouch Panel Programming

Press Start button sensors triggers, machine works on itself.

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.

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.

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.

Video ClipsVideo Clips

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.

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.

The endThe end