SITUATION
The customer wanted to automate a manual, labor-intensive adhesive application process for various sizes of lace material, applying adhesive and curing it with UV lamps within a tight working area. As a research and development project, Big Sky Engineering delivered a machine that exceeded the customer’s output expectations.
SOLUTION
Big Sky Engineering built the following line, running at 60 feet per minute with prep and cleanup under 30 minutes and support for multiple HMI recipes:
Preheater Assembly- Two pressure pots supply adhesive to the applicators, one on each side of the machine table, with pressure relief valves protecting the operator and bystanders.
Lace In-Feed- A wire brush contact keeps the lace oriented and snag-free.
In-Feed Dancer Pulleys- Keep the lace taut before it enters adhesive application station #1.
Driven Roller- Maintains consistent contact with the lace to keep it taut.
Adhesive Applicator- Touch-screen displays sit above the machine’s working area.
UV Lamp- Eight UV lamp units, adjustable through the HMI, cure adhesive on each side of the lace.
Lace Out-Feed- Driven rollers feed finished lace into the completed material box, with plexiglass guards protecting the operator from nip roller pinch points.
DESIGN FEATURES & SPECIFICATIONS
- Dual adhesive applicators
- Eight UV lamp assemblies
- Dual preheater assemblies
- Dual-language HMI display
- 60 feet per minute (FPM)
- Stack light indicators and illuminated control buttons show machine state
- HMI with icon-based controls and manual override mode
- Keyence laser sensors detect adhesive dot presence
Approximate Machine Dimensions: 197”L x 38”W x 105”H
Power Requirements: 240 VAC, 3-Phase, 60A
Pneumatic Requirements: 95 PSI, 2.0 SCFM
