When we wanted to install an automated system to help meet the volume and price demands of our blue chip customer (for the production of insert moulded sensor housings) we chose an Arburg Rotary table moulding machine with RNA automation and Fanuc robots.
The end-to-end manufacturing process, including loading inserts, moulding, checking if inserts are present, cooling, decay testing, and allows us to keep manufacturing in the UK.
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"Birmingham-based RNA, an automation integrator, partnered with Fanuc UK to produce a fully automated system for manufacturing, testing and packaging. Two Fanuc M10iA robots were integrated into the automated system.
When operating, two types of component parts (insert and antenna) are fed and orientated via two vibratory bowls and linear feed systems. The components are then fed into two independent precession shuttle mechanisms so that the insert and antenna are always in a known, repeatable and accurate positional location. A Fanuc M10iA robot is used with a double gripper mechanism to pick four inserts and four antenna from their locations. The inserts and antennas are placed in the correct orientation within the four-cavity moulding tool. Then a vertical moulding machine with a two-position rotary index table is used to enable simultaneous loading of inserts and antennas while the moulding process takes place.
On completion of moulding, the two position rotary index table actuates and presents an open mould tool to a second Fanuc M10iA robot. The mouldings are taken through an electrical test to check inserts are present and are moved to a specially developed cooling system based on a rotary table and cooling fans. This ensures parts are cool before leak decay testing. The mouldings are then placed into an automated packing area and in the final step empty boxes are fed from an in-feed conveyor to the packing area, where they are filled and transferred to the out-feed conveyor system.
Following the installation of the automated system at the R A Labone plant, Fanuc and RNA deployed engineers to train employees on how to set up, operate and maintain the automated system.
Benefits
Fanuc says the automated line provides a fully integrated and compact system increasing productivity, ensuring consistent product quality, reducing costs and minimising waste. It also increases precision, speed and accuracy when placing the inserts and antennas into the moulding tool. Reliability of positioning components is also ensured by high precision and accuracy of the handling processes.
It adds manufacturing efficiency and output have met the required targets as a result of the automated system, with 24-hour production. five days per week.
Alan Edmonds, head of technical sales, RNA, says: We chose Fanuc due to the speed and accuracy of the Fanuc robot and as part of a recommendation from R A Labone who already use Fanucs products and services. The automated system has completely transformed production capabilities for RA Labone and we have had further requests for future projects off the back of this success".