MU Project (Group 1)Automatic Epoxy Dispensing MachineCollaboration with Standard Success Groups Ltd.Chan Lai Yin 02061668dLaw Tsz Fung 02061668dLee Kit Chun 03401700dLi Wai Kin 03381120dNg Chin Yiu 03337129dWong Ching Hang 03015719dWong Ching Pong 03352040d

Project Supervisor Ir Robert Tam Technical Officer Mr Henry Wong

Mr C.K.Chiu

Introduction Collaborate with Standard Success

Groups Limited Design an epoxy filling machine

incorporated in production of Toroidal Transformer

Dimension of transformer1. Outer Diameter: 80~140 mm2. Overall Height: 40~110 mm

Introduction (Con’d) Formula of epoxy: 80%

of epoxy plus 20% curing agent

Average mixing time: 2 min

Average filling time: 19.95 m3 per second

Leakage of epoxy from the fixture

Scope of Project

Design an epoxy filling machine by using PLC

Design the appropriate fixture of holding transformers into position

Construct the fixture and machine

Objectives of design

1. To enhance productivity and efficiency

2. To improve the quality of products

3. To simplify labour workflow by automatic control

Factory Visit on 1/4/2006

Objective Deeper understanding of Background of

Factory and production process Technical Difficulties for reliability Possible Defect Realize the expectation from factory’s side Presenting to the personnel of our

preliminary design

Design Criteria

Easy to assembly, clean and undergo maintenance or overhaul activities

User friendly Economical of time and money in

manufacturing and production Effective in production

Process Flow of Machine

1. Locate the transformer (2) onto the fixture

2. Fill-in the mixed epoxy into tank

3. Filling time and volume of epoxy controlled by PLC automatically into the cavity

4. Take out the fixture from turntable

5. Put the fixture into oven

Design AlternativesDesign 1

Specification of Design 1:

•Three dispensing heads.•Easy to clean through one main channel.•Simple to just fill one mixing tank.

Hard to maintain the same pressure and flow amount of each head.Imperfect product would be the result.

Design 2Specification of Design 2:

•Easy to assembly by rivet system•Easy to clean as using plastic bag to wrap the surface•Easy to disassembly by loosening the rivet for cleaning

The flow of epoxy may not be easy without the sliding angleThe rivet pattern will be loosened by frequent use.

Design 3

Specification of Design 3:

•Modification of Design 2

•Easy flow for the epoxy with a sliding angle in the tank

•Reliable screw system for easy assembly and disassembly

Dispenser

Design Alternatives (Conveyer)

Advantages: Continuous

processing (can link with other machines)

Easy to assembly and make adjustments

The availability of the conveyer is high in the market

Design Alternatives (Conveyer)

Disadvantages The system may require

a lot of servo-motors and sensors

Relative low production rate (single line production)

Expensive

Outlook of the whole systemDispenser System

Turntable

Filling of Epoxy

Tank

Epoxy Container

Dispenser Valve Unit

Dispenser valve unit

Cylinder

Closing of Hole

Opening of Hole

Epoxy Output

Epoxy Injector(Changeable)

Pressure

Turntable Rotate

Our Prototype

Our Prototype

Cost Calculation

Parts Prices

Mechanical parts Yee Fu Engineering & Trading Co.

$ 7,030.4

Pneumatic parts and control units

SMC Mitsubishi

$ 10,286.8

Electrical parts RS Hong Kong

$ 2,758.2

Manufacturing (MMU) These parts are mainly

made by cutting, milling and turning machines in the MMU workshop.

Aluminum profile cutting Blocks milling Discs and some parts

turning Drilling holes Taping

Manufacturing (2)

High surface finishing and low tolerance Parts are made in CNC workshop. Bearing covers turning Plates drilling

Complicated shape discs are made by wire cutting machine.

Manufacturing (3) Sheet metal

workshop To fold the PLC

control box.

Welding workshop To weld the tank

of dispenser.

Manufacturing (4) Turntable main

mechanism is mainly made in the CNC workshop Bearing covers Shaft

Manufacturing (5)

Turntable main mechanism includes different sizes of bearing

Fitting bearings require much more accuracy

CNC machining can produce more reliable parts

Manufacturing techniques All parts’ edge should be

removed to be chamber. Use grinding machine to

unify same parts’ height and increase the surface finishing.

To turn and mill stainless steel parts, using carbon tools is recommended instead of high speed steel tools.

Sequence

PLC I/O diagram

Circuit Diagram

Touch panel

Software can create the screen and then input the screen to the PLC.

Preset instructions will allow user to control the machine by panel buttons

Touch panelThe keyboard page helps user to change the time by panel

Using the PLC memory to save the value and then for the further operation

Planning (25Feb-29Apr) Analyzed the project Visited the Standard Success Groups Ltd. Estimated the budget Proposed the design ideas Drew the design ideas by using CAD software Presentation to the client Made changes on the design to meet clients'

requirements Improved our design and inform our clients Training on the PLC control system Documentation (BOM) Sent BOM to preserve materials for manufacturing

Planning (24May-28Jun) 24May-27May

Preparing the profiles Amending the CAD drawing

29May-10Jun Manufacturing of the valve system for the

dispensers Manufacturing of parts of the turntable Testing the PLC devices and writing the PLC

program

Planning (24May-28Jun) 12Jun-24Jun

Manufacturing of the remaining parts of dispensers

Manufacturing of the main shaft for turntable Manufacturing of the control box Program Debugging Fine tuning of the manufactured parts

26Jun-28Jun Fine tuning of the manufactured parts and PLC

system Assembly of the whole device Preparing stuff for presentation

Division of work

Name Responsibility

Chan Lai Yin, Lee Kit Chun, Li Wai Kin, Wong Ching Hang

Design and manufacturing of dispenser and turntable

Documentation, Website

Law Tsz Fung, Ng Chin Yiu, Wong Ching Pong

Design and manufacturing of turntable

Control system

The whole group Presentation

Learning Outcome

We are familiar with

Dispensing system Parts for dispensing function

PLC Control system PLC parts Selection of the suitable candidates for design Programming Testing

Learning Outcome Problem solving skills

Solve the problem between theory and reality Contingency plan

Co-operation skills Communication among our group Different processes undergone at the same time Communication between each workshop

Conclusion From IC Centre

Tell us, we will forget; Show us, we will remember; Let us do it, we will understand.

告訴我 , 我會忘記 讓我看 , 我會記起 讓我做 , 我會明白

Automatic Epoxy Dispensing Machine

The End

Thank you!

Question and Answer