SITUATION
The customer was expanding into a new production facility and wanted to automate valve packaging and part inspection, replacing a manual process that required close monitoring and heavy physical labor. The machine needed to run fully autonomously at a packaging rate of 15 parts per minute (PPM), with changeover under 10 minutes, multiple HMI recipes, and compliance with NFPA 79, OSHA, UL, and NEC requirements.
SOLUTION
Valve Part In-Feed- A driven conveyor supplies valve parts to the machine.
Valve Guide Pick- A Fanuc robot with a parallel jaw gripper picks each part and positions it at the camera and micrometer inspection stations.
Micrometer- A digital micrometer checks the part’s edge and interior for flaws; rejects go to the reject chute on top of the machine table.
Camera Inspection- Scans the part edge for flaws; rejects go to the same reject chute.
Array Building Table- Parts that pass inspection are placed on the array building table.
Part Transfer- A vacuum pickhead picks parts from the array building table, and a gantry positions the pickhead into the case.
Case Handling- Powered roller conveyors move cases into the box loading zone, where corner clamps and vertical clamps secure the case, with plastic lining installed, through the fill cycle.
Inspection Display Screens- Exterior-mounted displays show live machine results.
DESIGN FEATURES & SPECIFICATIONS
- Fanuc LR Mate 200iD with a rotating swivel head and gripper tool picks and places valve components
- Keyence TM-040 optical micrometers
- Keyence defect camera inspection system
- Dual-language HMI display
- 4-second cycle time
- Stack light indicators and illuminated control buttons show machine state
- HMI with icon-based controls and manual override mode
- In-table reject bin keeps operators and bystanders clear of machine hazards
- Powered roller conveyors
- Allen-Bradley PLC control package and HMI
Approximate Machine Dimensions: 114”L x 60”W x 93”H
Power Requirements: 480 VAC, 3-Phase, 30A
Pneumatic Requirements: 80 PSI, 30 SCFM
