MU Project (Group 1) Automatic Epoxy Dispensing Machine Collaboration with Standard Success Groups Ltd. Chan Lai Yin 02061668d Law Tsz Fung Lee Kit Chun 03401700d Li Wai Kin 03381120d Ng Chin Yiu 03337129d Wong Ching Hang 03015719d Wong Ching Pong 03352040d Project Supervisor Ir Robert Tam Technical Officer Mr Henry Wong Mr C.K.Chiu

Introduction Collaborate with Standard Success Groups Limited Design an epoxy filling machine incorporated in production of Toroidal Transformer Dimension of transformer Outer Diameter: 80~140 mm Overall Height: 40~110 mm

Introduction (Con’d) Formula of epoxy: 80% of epoxy plus 20% curing agent Average mixing time: 2 min Average filling time: 19.95 m3 per second Leakage of epoxy from the fixture

Scope of Project Design an epoxy filling machine by using PLC Design the appropriate fixture of holding transformers into position Construct the fixture and machine

Objectives of design To enhance productivity and efficiency To improve the quality of products To simplify labour workflow by automatic control

Factory Visit on 1/4/2006 Objective Deeper understanding of Background of Factory and production process Technical Difficulties for reliability Possible Defect Realize the expectation from factory’s side Presenting to the personnel of our preliminary design

Design Criteria Easy to assembly, clean and undergo maintenance or overhaul activities User friendly Economical of time and money in manufacturing and production Effective in production

Process Flow of Machine Locate the transformer (2) onto the fixture Fill-in the mixed epoxy into tank Filling time and volume of epoxy controlled by PLC automatically into the cavity Take out the fixture from turntable Put the fixture into oven

Design Alternatives Design 1 Specification of Design 1: Three dispensing heads. Easy to clean through one main channel. Simple to just fill one mixing tank.  Hard to maintain the same pressure and flow amount of each head. Imperfect product would be the result.

Design 2 Specification of Design 2: Easy to assembly by rivet system Easy to clean as using plastic bag to wrap the surface Easy to disassembly by loosening the rivet for cleaning  The flow of epoxy may not be easy without the sliding angle The rivet pattern will be loosened by frequent use.

Design 3 Specification of Design 3: Modification of Design 2 Easy flow for the epoxy with a sliding angle in the tank Reliable screw system for easy assembly and disassembly

Dispenser

Design Alternatives (Conveyer) Advantages: Continuous processing (can link with other machines) Easy to assembly and make adjustments The availability of the conveyer is high in the market

Design Alternatives (Conveyer) Disadvantages The system may require a lot of servo-motors and sensors Relative low production rate (single line production) Expensive

Outlook of the whole system Dispenser System Turntable

Filling of Epoxy Epoxy Container Tank Dispenser Valve Unit

Dispenser valve unit Cylinder

Closing of Hole Opening of Hole

Epoxy Output Pressure Epoxy Injector (Changeable)

Turntable Rotate

Our Prototype

Our Prototype

Cost Calculation Total: $ 20,075.4 Parts Prices Mechanical parts Yee Fu Engineering & Trading Co. $ 7,030.4 Pneumatic parts and control units SMC Mitsubishi $ 10,286.8 Electrical parts RS Hong Kong $ 2,758.2 Total: $ 20,075.4

Manufacturing (MMU) These parts are mainly made by cutting, milling and turning machines in the MMU workshop. Aluminum profile cutting Blocks milling Discs and some parts turning Drilling holes Taping

Manufacturing (2) High surface finishing and low tolerance Parts are made in CNC workshop. Bearing covers turning Plates drilling Complicated shape discs are made by wire cutting machine. Some parts that are required high surface finishing and low tolerance has been done in the CNC workshop.

Manufacturing (3) Sheet metal workshop Welding workshop To fold the PLC control box. Welding workshop To weld the tank of dispenser.

Manufacturing (4) Turntable main mechanism is mainly made in the CNC workshop Bearing covers Shaft

Manufacturing (5) Turntable main mechanism includes different sizes of bearing Fitting bearings require much more accuracy CNC machining can produce more reliable parts

Manufacturing techniques All parts’ edge should be removed to be chamber. Use grinding machine to unify same parts’ height and increase the surface finishing. To turn and mill stainless steel parts, using carbon tools is recommended instead of high speed steel tools.

Sequence

PLC I/O diagram

Circuit Diagram

Touch panel Software can create the screen and then input the screen to the PLC. Preset instructions will allow user to control the machine by panel buttons

Touch panel The keyboard page helps user to change the time by panel Using the PLC memory to save the value and then for the further operation

Planning (25Feb-29Apr) Analyzed the project Visited the Standard Success Groups Ltd. Estimated the budget Proposed the design ideas Drew the design ideas by using CAD software Presentation to the client Made changes on the design to meet clients' requirements Improved our design and inform our clients Training on the PLC control system Documentation (BOM) Sent BOM to preserve materials for manufacturing

Planning (24May-28Jun) 24May-27May Preparing the profiles Amending the CAD drawing 29May-10Jun Manufacturing of the valve system for the dispensers Manufacturing of parts of the turntable Testing the PLC devices and writing the PLC program

Planning (24May-28Jun) 12Jun-24Jun Manufacturing of the remaining parts of dispensers Manufacturing of the main shaft for turntable Manufacturing of the control box Program Debugging Fine tuning of the manufactured parts 26Jun-28Jun Fine tuning of the manufactured parts and PLC system Assembly of the whole device Preparing stuff for presentation

Division of work Name Responsibility Chan Lai Yin, Lee Kit Chun, Li Wai Kin, Wong Ching Hang Design and manufacturing of dispenser and turntable Documentation, Website Law Tsz Fung, Ng Chin Yiu, Wong Ching Pong Design and manufacturing of turntable Control system The whole group Presentation

Learning Outcome We are familiar with Dispensing system Parts for dispensing function PLC Control system PLC parts Selection of the suitable candidates for design Programming Testing

Learning Outcome Problem solving skills Solve the problem between theory and reality Contingency plan Co-operation skills Communication among our group Different processes undergone at the same time Communication between each workshop

Conclusion From IC Centre Tell us, we will forget; Show us, we will remember; Let us do it, we will understand. 告訴我,我會忘記 讓我看,我會記起 讓我做,我會明白

Automatic Epoxy Dispensing Machine

The End Thank you!

Question and Answer