Overview of some of my recent projects:
Materials handling system for outfeed of U-section bars from continuously
running roll-forming line. (BHP)
This requirement involved positioning of length of material on roll conveyor
and shifting it sidewise for precise alignment. This was achieved by shifting
bars, connected to overhead group of chains driven by speed controlled
motor for controlled start-stop operation. Bars are then moved by custom
designed magnetic conveyor to palletising station. During this stage every
second bar is turned 180deg and nested into previous one. This uses permanent
holding magnets and number of pneumatic cylinders for switching of magnets
and for moving positioning stops. Palletising station is designed to create
pack of nested profiles and present it for manual bundling and removal
via heavy duty roll conveyor.
Patent applicaton for some design features
was under consideration.
My involvement was:
-
development and evaluation of possible approaches to problem
-
design of actual solution
-
development and supervision of manufacture of prototypes of subsystems
-
significant participation in development of program for servo drive
-
development and design of final system
-
supervision of manufacture and assembly of final system (under very strict
schedule and budget)
-
supervision of designer and workshop operators
-
management of suppliers and subcontractors
Redesign of security grille production line for higher throughput. (Juralco)
Project involved production line which I designed for Juralco a few years
before (while on staff). It is quite a complex system which involved use
of pneumatic systems, hydraulic systems, number of custom developed chain
conveyors and very complex and quite unusual control software. Line was
running successfully but Juralco needed a second one and I was asked to
help with "touch-up" of documentation. I agreed but after evaluation of
requirements and cost effectiveness of this approach I suggested that upgrade
of the line will be much easier for following reasons -
-
original specification asked for 1 grille every 60 seconds - this was achieved
but after practical experience it was obvious that most subsystems have
some reserve and remaining ones can be upgraded
-
upgrade will cost much less than second machine,
-
Juralco needed higher output than one line can provide but not quite double
of it
-
upgrade would not take factory area (significant aspect as machine is over
25 m long and requires about 6 m wide bay)
-
materials handling of raw material and finished product will be much easier
with single line
-
only one crew of 2-3 operators is needed for required production
-
upgrade can be done in stages starting almost immendiately therefore giving
production which is well matched to rising requirements, without necessity
to commit full investment for the second line
I did work in my home office and visited Adelaide factory a few times during
project. Drawings were sent to Adelaide by e-mail and there was almost
daily exchange of ideas and problem solutions by e-mail (we found that
it is much more convenient than phone calls). My involvement was:
-
development and evaluation of possible approaches to problem
-
design of actual solution
-
redesign of very complex PC based control system for faster operation and
higher number of I/O
-
setting up and preliminary trials of this PC based control system in my
home office
-
design of updated control system and supervision
of program development
Packaging machine for rubber gloves. (Invetech)
This project required forming of well controlled pack of medical gloves.
Most difficult part was to find out how to recognise correct position of
thin rubber glove without artificial intelligence and a huge computing
power. Required throughput was also quite high. Resulting machine used
number of very simple sub-lines running in parallel. Pneumatics and vacuum
was used for most operations and sophisticated PLC software tailored to
very fast process was needed for reliable function.
This project become one of The 1996 Victorian
Engineering
Excellence Awards winners under name of "Automated Layer Packaging
of Examination Gloves project".
Main features are currently subject of patent
applicaton.
For result see in Invetech
Newsletter - "Automation at Ansell International"
My involvement in development of prototype was:
-
development and evaluation of possible approaches to problem
-
development of cheap ways of evaluation of behaviour of fast moving glove
-
development of actual solutions
-
participation in design of prototype
-
participation in development and supervision of manufacture of prototypes
of subsystems
-
development of PLC program
-
participation in supervision of manufacture, assembly and testing of prototype
Common points:
-
materials handling forms a significant part of project
-
sophisticated PLC or PC based control system is used
-
use of pneumatics, hydraulic and servo drives or speed controlled motors
-
innovative and often unusual solution is used (all machines are - or could
be - subject of patents)
-
good team work contributed to - or was essential for - success of project
Last Updated: 10.11.1997