Customized plant engineering – assembly, joining and testing system for caustic tanks

Workpiece:

Caustic tank, cover, roller bearing, shaft seal, earthing plate

Task:

Development and manufacture of a semi-automated system for the assembly and testing of caustic containers.

Solution:

The caustic containers with molded-in hubs produced in an injection molding machine provided by the customer are placed on special workpiece carriers. The workpiece carriers are transported through several stations of the assembly system via a TECHTORY transfer system with accumulation roller chain. The workpieces are returned to the starting point via lift stations and a return line. In the welding station, a lid previously inserted manually by the worker is welded into the base of the container using an ultrasonic welding process. After moving on to the testing station, the component and the weld seam are tested for leaks. After manual insertion of the individual parts, a bearing is first pressed in from below in the subsequent assembly station, followed by the second bearing from above and then the sealing ring. This is followed by the assembly of the earthing plate, which is electrically tested immediately afterwards. Once the conductivity test has been passed, the container is marked. In the removal station, the finished containers are placed on an OK or NOK belt using a suction gripper. Good parts are manually labeled by the worker with a label provided.

Customer benefits:

• Optimized partial automation for short amortization time
• TECHTORY transfer system with lift stations and return of the WT
• Shutter between the individual processing stations to prevent accidents
• Automatic lifting door for optimum accessibility
• Checking the correct insertion of individual parts using sensors and a vision camera
• Consideration of customer specifications for ergonomics and workplace design