How can robotic automation improve efficiency in manufacturing processes?

Our robotic automation solutions dramatically boost efficiency in manufacturing by enhancing speed, precision, and consistency. We focus on minimizing manual errors, accelerating production rates, and ensuring safety by handling repetitive and hazardous tasks.

What are the different types of robotic automation systems available for manufacturing applications?

We offer a range of robotic automation systems for manufacturing, including SCARA and Delta robots. SCARA robots are ideal for precision tasks requiring speed and compact design, while Delta robots excel in fast, repetitive actions like picking and placing.

What types of defects or issues can vision inspection systems detect in manufacturing?

Our vision inspection systems are adept at detecting dimensional inaccuracies, surface defects like scratches or dents, misalignments, and incorrect or missing components. They are also capable of verifying label accuracy, barcode readability, and color consistency.

What types of manufacturing tasks can be performed using a rotary indexing machine?Rotary indexing machines at Big Sky Engineering are highly versatile, designed to perform a range of precise manufacturing tasks. They are ideal for assembly, drilling, precision machining, and quality inspection. These machines excel in high-volume production environments, offering accuracy and repeatability.

Rotary indexing machines at Big Sky Engineering are highly versatile, designed to perform a range of precise manufacturing tasks. They are ideal for assembly, drilling, precision machining, and quality inspection. These machines excel in high-volume production environments, offering accuracy and repeatability.

Lid Assembly, Stacking & Case Packing - Big Sky Engineering, Inc

SITUATION

The customer needed a complete closure assembly, inspection, and packing machine with overhead conveyor systems.

SOLUTION

Lid Infeed Conveyor- Lids enter single-file, open-side down, in random radial orientation. An overhead Fanuc iR vision camera and conveyor encoder track each lid’s position and orientation for the pick-and-place robots.
Robotic Pick and Placement- Two Fanuc SR-6iA SCARA robots per side, fitted with vacuum end-of-arm tooling, continuously pick lids and place them onto the indexing conveyor fixtures in the correct radial orientation.
2-Up Indexing Conveyor- Maintains lid orientation through assembly and stacking, housed in a welded structural steel frame that supports the rest of the system.
Cap Feed and Installation- Operators load caps into a 15-cubic-foot bulk pre-feeder, which meters caps to a vibratory feeder bowl that orients them open-side down. A two-axis gantry with powered rotary actuators picks and installs two caps at a time.
Vision Inspection- Inspects the lid assembly for label placement and flash before the indexing machine, ejecting rejects.
2-Up Up-Stacking- Lifts lids from underneath through the carrying fixtures to form vertical logs, two per side.
Robotic Case Packing- A Fanuc M-10iD/12 robot with a high-flow vacuum EOAT picks completed logs by count and places them into the case at programmed pack positions.
Case Handling and Locating- Powered roller conveyors bring cases through a short U-shaped travel path, with room for an optional case labeler. The case is located and held in a “shoe-horn” position to fit as many lids as possible.

DESIGN FEATURES & SPECIFICATIONS

4 lid infeed conveyors with overhead iR vision line tracking
4 pairs of Fanuc SR-6iA SCARA robots with specialized lid vacuum EOAT
4 cap bulk feeder elevator conveyors
4 cap orient-and-feed systems
4 cap pick-and-place mechanisms
4 torque application stations
4 cap cross-thread check stations
Keyence camera solution with specialized LED lighting
4 independently servo-controlled up-stacking stations with accumulation magazines
4 vertical stacked-log transfer actuator stations
Fanuc M-10iD/12 case packaging robot
10″ PanelView Performance HMI and safety PLC module

Approximate Machine Dimensions: 68’L x 24’W x 15’H

Power Requirements: 480 VAC, 3-Phase, 100A