Random Walk Through Costco with Moog Animatics and SmartMotor
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Transcript of Random Walk Through Costco with Moog Animatics and SmartMotor
A Random Walk Through Costco with Moog Animatics
LCD and Plasma Displays: SmartMotor™ products are used
in coating process for Backlight film
SmartMotors are used in metalizing and coating process of glass layers.
Electronics
Electronics
Heat shrink wrapping on CD/DVD packages
Tubes are fed down over packaging, plastic is dispensed and air is blown through before being shrunk to form fit the container
Clothing
Fabric Sewing : Inseams on pants & Sleeves on shirts
SmartMotors are used in various textile industries. One example is the high speed stitching of inseams on pants.
Through the use of feedback, thread tension can be controlled.
Looper motors and material feed motors utilize electronic gearing off of main sewing head motor
Appliances (Filters)
Traverse & Take-up Winding Also used for making swimming pool
filters Cotton based water filtration systems
Guitars
Guitar String Manufacturing Same process / SmartMotor application
as catheter manufacturing (Traverse & Take-up Winding)
Allowed foot pedal controls without need for any PC or PLC
Precise electronic gearing with phase offsets increased throughput and quality
2 Rotary index tables working in unison. Main table, table in cam mode to spot
weld clamps on sink With I/O and control capabilities, dwell
can be defined by end of process state (welding completion) to improve overall production cycle times
Kitchen Products
Batteries- battery cell plates inserted, UV weld placed around top, butane deburring machine (plastic reflow)
Automotive
5 Gallon Buckets
5 gallon bucket label application Bucket spins as barcode and label is
applied Motors feed label material and rotate
bucket. Motion added to PLC without cost of
motion control card
Bicycles
Front and rear fork destructive testing via vibration
Motor cycles through constant force over extended position swings to point of failure.
Data logged via load cell directly into motor for strength testing
Bypassed need for PLC or data acquisition cards.
Outdoor Products
Automated assembly machines for manufacturing of gas regulator valves and fittings and hot water heater overpressure valves
Large axis count mounted on rotating assembly table allowed power and communications via slip rings.
No drive and control cables to run back to control panels.
Each motor handled local tasks and I/O
Outdoor Products Fiberglass rods cut to length from
continuous-feed extrusion. (Cutting process)
Additionally, With the ability to program up to 1000 subroutines and 32K of extra data storage, the system can be programmed for hundreds of back stop positions and sequences.
No external PLC or PC would be required. A simple HMI can be utilized for interfacing
Outdoor Products Surfboards!
Outdoor Products
Kayaks / Canoes Cutout of plug for top of kayak with a
router Butane deburring process (ABS plastic)
Beverages Kuka robot, with 4 axis SmartMotor
end-effector, both clamps onto and shifts cases for proper orientation on conveyor
Integrated controls allowed for light weight simple design at end effecter with only power and communications connections.
Full error checking and diagnostics all within SmartMotor subroutine control
Grocery
Ziploc-style bags (for numerous products), thin film laminate feed, folded over, heat sealed with alignment check
Labels applied to registration marks Automatic Closed loop edge guide of
film to insure alignment of zip lock mating surfaces controlled entirely by SmartMotor program
Grocery Pre-stacking of crackers and heat
sealing of plastic in box. Utilizing subroutines and variable
counter, both Absolute and Relative Position Mode moves allow for start of stack and incremental stack shifts while maintaining parts counts.
Having localized I/O within the Integrated Controls, the entire handling of parts can be dealt with by the stacker motor itself.
True distributed control at a fraction of the cost and footprint.
Grocery
Cut to length and fill of film for trash bags, palletizing of product array
Take-up winding application SmartMotor driven toggle press for
closing jaws in cut & seal process
Grocery
“Mystery eggs” - inseminating, pre-process
Gantry moves over egg array(?) Customer required remote serial control
in simplistic language for both manual over ride and automatic control
Grocery
Combination of Stack lifter and rotary carousel rotates multiple stackers to tube of plastic for packaging.
Stacker Motors rotated with table Only power needed to be fed to
carousel.
x 5
Eyeglasses & Contacts
Lens cutting and grinding Mold & packaging process for contact
lenses Several motors deployed for in-line
assembly, transfer, inspection, and packaging of product
Allowed multi axis control over simple RS232 communications back to PLC
No large control cabinet required due to integrated controls
Cotton Industry
Testing of softness of cotton in compression
Done for Federal agricultural agency testing on an extremely large scale
30+ motors used through various stages of product transfer, compression, tension and density testing
Simplistic approach saving hundreds on cabling and panel space
Quilting operations – Custom patterns and edge quilting
Full CNC At-home quilting machines now available for end users allowing custom record and playback quilt patterns
Bedding
Bedding
Quilted stitching of edges and main seams
Glue application of rows of pocketed inner springs.
Automated feed of each additional rows of mattress inner springs
Motor traveled with glue dispense head controlling both motion and glue pump and valves
Relieved main PLC of motion tasks allowing faster throughput
Bathroom Articles
Toothbrush handles (robotic extraction out of the mold)
SmartMotor used in robotic arms for extraction of handles
Also various other mold injection formed plastic pieces
Bathroom Articles
Diapers and other hygiene products On-the-fly insertion of absorbent
material Application of adhesive strips Motors on rotary Ferris wheel type
mechanical setup run in CAM mode Only integrated solution with CAM
mode available!
Detergent
Numerous capping and filling operations
Automated rail adjustment for rapid change over
Using size 34 frame motors to lift entire bed of machine for height of dry powder detergent.
Cable runs from control cabinet exceeded 80 feet. Conventional drives would have used too many sub panels and cable ways
Breathmints
Tic-Tacs® and Listermint® Breathmints Plastic case inserting and labeling Take-up of film, cutting, stacking, and
placement in cases. Entire process run by SmartMotors
alone
Vitamins/ Pharmaceutical
Bottle cappers and bottle filling for various small plastic bottles including:
Vitamins Over-the-counter drugs Automated prescription fillers
Tires & Wheel Rims
Tires spun and tread surface is finished if out-of-round
Replaced Delta Tau 6-axis System at a cost savings of over $8K on next generation machines.
CNC cutting of metal wheel rims deployed later to create dedicated CNC rim machine for one-off custom designs
Door and Cabinet Manufacturing Horizontal boring drill units are positioned
in matched patterns to part numbers via HMI and SmartMotor array data look-up.
Set rotating Motor as master and have the linear axis electronically gear off of it to provide high speed drill and taps and screw feed control with limited torque.
Adding proper torque detection, the unit can detect when a drill or tap has worn or become dull. As a nut/screw runner, it can pick up on cross thread, broken or stripped thread, missing part or jammed part
MOOG ANIMATICS
Everywhere!