419-726-7400Choose a case study to learn more:
CASE STUDY 1
UPGRADING A CUT TO LENGTH SYSTEM CASE STUDY 2
AUTOMATION OF AN ASSEMBLY CELL CASE STUDY 3
DESIGN AND BUILD OF AN AUTOMATIC ASSEMBLY MACHINE CASE STUDY 4
HIGH SPEED PLASTIC TRIM/CUT/SCRAP REMOVING MACHINE
CASE STUDY 1 – UPGRADING A CUT TO LENGTH SYSTEM
THE PROBLEM
To produce a higher quality, cut to length, Multi Port Extruded, (MPE), tube faster than current technology allowed.
The client manufacturers MPE tubing for automotive and truck air conditioning exchangers. Existing equipment uncoiled and cut the part at a rate of approximately 40ppm. Additionally, after the MPE material was uncoiled and the cut into the appropriate lengths, they were hand inspected and hand packaged before being shipped to the customer. This procedure resulted in high labor costs with a low quality product that was often rejected by their customer.
THE PD&B Inc. SOLUTION
PD&B Inc. supplies one of the highest speed, if not the highest speed, complete cut-to-length lines in the world. It is fast and incredibly accurate. Depending on part size and construction, it can “gently” produce parts at speeds of 350ppm; all while holding extremely tight dimensional tolerances. For example, height can be maintained at +/- 0.010mm or better using two of the optional PD&B Inc. ultra precision part sizing stations. Width, bow, camber and length maintain similar levels of precision.
Combined with the precision and speed the PD&B Inc. equipment has to offer this line also incorporates high speed inspection and packaging. This allows even more time for the operator to attend to other functions within his or her scope. It should be mentioned that one operator is being used in some plants we supply to run two lines simultaneously. There rates are close to 700 parts per man minute or 17.5 times the original rate or 40 ppm.
Any of our Micro Tube or Multivoid aluminum tubing manufacturers will tell you, the levels of performance are unsurpassed with the PD&B Inc. High Speed Cut to Length line. Moreover, the many lines we have in the field are a testimonial to the durability and longevity as well.
CASE STUDY 2 – AUTOMATION OF AN ASSEMBLY CELL
THE PROBLEM
Too much labor in the assembly of a Jeep Grand Cherokee head light bracket.
PD&B Inc. was asked to provide a solution to an assembly bottleneck being experienced by an automotive tier one supplier. In their request, the customer spelled out that they wanted to automatically insert M6 and M8 nuts into a headlamp bracket, check for proper insertion, apply a bar code label and ensure that the part was correct before releasing it to the operator. All of this had to happen in less than 30 seconds.
THE PD&B Inc. SOLUTION
PD&B Inc. was happy to help them by designing and building a robotic assembly cell. It was composed of a Fanuc robot, servo driven slides, custom tooling, a customer specified PLC and a Proface/Xycom Operator interface. The machine is currently up and running at rates exceeding customer expectations. It runs smoothly and safely with redundant safety systems. A reduction in the number of personnel resulted in a 6 month payback on the cell.
CASE STUDY 3 – DESIGN AND BUILD OF AN AUTOMATIC ASSEMBLY MACHINE
THE PROBLEM
A Northwest Ohio company had four employees that were assembling approximately 400 hinges per hour. That plant manager wanted to improve the efficiency of the plant.
THE PD&B Inc. SOLUTION
So, PD&B Inc. engineering went to work to design and build an automatic HINGE ASSEMBLY MACHINE. Within a week, we presented a concept of a machine that was estimated to produce 650 parts per hour. He liked it, we quoted it, he approved it, and then issued a purchase order.
The six station dial pictured above is the end result. Primary control is supplied by an Allen Bradley PLC. It also utilizes two Dixon nut drivers, an Industrial Feeders bowl feeder for bolt placement, and 601RDM Camco indexer to rotate the dial.
During the run off at our facility, we were able to run the machine at 850 parts per hour. The customer was understandably excited. We were too. As of today, approximately 3 years later, the machine is running flawlessly at 910 parts per hour. Our customer is now able to manufacture in the US for less money than he thought possible, and, it allowed him to maintain production in his Ohio facility. Incredibly, maintenance estimated a 3.5 month payback!
CASE STUDY 4 – HIGH SPEED PLASTIC TRIM / CUT / SCRAP REMOVING MACHINE
THE PROBLEM
To support the upstream blow molding equipment with plastic processing machinery at the speeds the line was capable of.
A US manufacturer needed downstream equipment to de-flash blow molded totes. They had recently developed a brand new way of manufacturing the product at a much higher rate. The process prior to their new equipment required trimming a tote every two and half minutes.
THE PD&B Inc. SOLUTION
PD&B Inc. provided a solution that de-flashed three parts simultaneously, on two machines, to achieve the rate needed. One of the machines, in assembly, is pictured above.
Once completed, the PD&B Inc. equipment shortened the cycle time down to one tote every three and half seconds. Up until that point there was no equipment available up to the task.
The process begins with an input conveyor loading three totes into separate escapements, which ultimately “push” them into the trim station. Once they are in position each tote is raised into a cam-guided cutter head to cut the flashing off the container. The two trimming knives are guided in the X, Y, and Z planes. Upon completion, all three totes are pushed out the back side of the machine onto the exit conveyor for transportation to shipping.
