1. ASTRRA™ Automated Changeover System
Transforming Mechanization into Automation
A. S. Thomas Remote Resource Automation
Application Example:
Conveyor Guide Reconfiguration
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2. ASTRRATM History of A. S. Thomas, Inc.
Founded in 1955 at the request of the US Department of Defense for the research and development for the detection and tracking of a missile launch any where in the world. The technology developed by A. S. Thomas, Inc. is still classified to this day.
Develop the heat shielding of re-entry vehicles both manned and unmanned to minimize the interruption in communications .
Developed the stealth technology in use today.
Developed factory automation systems for use in discrete manufacturing. Control conveyors, car tracks wire guided and wireless transport systems, track part pedigree from raw material to finish goods, robotic part transfers, etc.
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3. ASTRRATM ASTRRA is a revolutionary change over system
ASTRRA uses automation instead of mechanization and manual operations to perform change over tasks
The ASTRRA system consists of linear and rotary actuators, control system and software to perform the tasks
ASTRRA will help your business by:
Improved worker safety
Center-lined process
Accurate and repeatable change over
Greater flexibility
Increased uptime and production throughput
ASTRRA very high value per dollar
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4. ASTRRATM Automation vs. Mechanization vs. Manual
What’s the difference?
Manual human operators perform the work
Mechanization uses machines to leverage labour
Automation is flexibility and unattended performance
Manufacturing automation provides unprecedented lower unit cost due to:
Safety
Flexibility
Uptime
Reliability
Return to Normal
Quality
Security
The result: dramatically improved efficiency and cost savings
mechanization provides human operators with machinery to assist them with the physical requirements of work, automation greatly reduces the need for human sensory and mental requirements as well.
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5. ASTRRATM Introducing Automated Rail Changeover
ASTRRA sets rail positions via computer-controlled adjustment actuators throughout your packaging line:
Set, store, and recall an unlimited number of recipes for plant-wide conveyor rail and equipment positions
Change all positions by clicking a new recipe on a menu-driven user interface
Automatically implement many types of adjustments, both linear and rotary
Fine-tune positions without halting production
Easily retrofit existing machines and conveyors
Flexible architecture that allows for phased installation
Low cost of implementation
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6. ASTRRATM Unparalleled Accuracy & Repeatability
ASTRRA combines precision positioning with speed unobtainable with manual or mechanized changeovers:
0.1257mm position accuracy assures return to normal every time
0.25mm position repeatability eliminates the variability of manual changeovers
Controls both straight rails and variable-radius arcs
Linear actuators ranging from 50mm to 200mm
Rotary actuators range from 50 to 100
Every actuator is infinitely adjustable with its range
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7. ASTRRATM Multiple Communications Options
ASTRRAbus vs. ASTRRAnet
ASTRRAbus is a low wire solution
Modbus RTU on an RS wire system
Ideal for monoblocks and low count (<32 units)
38.5Kbs with 4000' data bus length
ASTRRAnet is a wireless solution
IEEE with MiWi protocol
Up to 120 units/segment
250/625 Kbs with 4000' range (2 Mbs coming Q2'11)
More robust
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8. ASTRRATM Benefits Boost Efficiency and Profit
ASTRRA automation brings flexibility which translates to direct bottom-line benefits:
Improved worker safety helps prevent injuries
Actuators eliminate need for hands-on changeovers
Overhead conveyors can be changed without endangering personnel
Repeatable positioning ensures safe operation
Remote control enables positions to be fine-tuned while line is running without compromising safety
Improved discipline avoids needless downtime
Improved efficiency increases uptime
Accurate changeovers reduce downtime; frees skilled trades to perform other value added maintenance tasks
High repeatability eliminates ramp-up time due to changeover lack of return to normal
Remote fine-tuning allows for easy addition of new products
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9. ASTRRATM Automatic Changeover Equipment
Conveyor Guide Railing Example
Status
LEDs
Master Actuator
Slave Actuator
Expansion Port
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10. ASTRRATM Easily Accommodates Arc Regions
Arc sections are handled
the same as straight
sections
True arc
Rigid
Change parts are no
longer required to
ensure accurate,
rigid corners
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11. ASTRRATM Standard, Intuitive Operator Interface
Make adjustments from master controller (ATOMICS), ASTRRA Sequence Coordinator or PC
System allows for direct observation of setup and changeovers
Press the photo to do a Change Over
Intuitive, self-explanatory screens
Minimal training required
Highly practical and robust
Integrates with other applications
Stable platform
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12. ASTRRATM Multiple Control Modes Provide Flexibility
Operator interface enables new package changeover positions to be specified in 3 ways:
Direct-specification mode enables all rails to be repositioned based on entering package control width
Recipe-edit mode enables new recipes to be based on adjustments to previously stored recipes
Fine-tune mode enables supervisors to introduce new positions to build a new recipe one actuator at a time
ASTRRA allows for a perfect change over first time and every time
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13. ASTRRATM Implementation Benefits
ASTRRA is economical to install and operate:
Actuators only require one 24V DC bus for power
Wireless control eliminates bulky, costly to install PLC wiring harnesses
Well insulated power wiring safe even in wet environments
Patented architecture makes even large, multipoint systems inexpensive to operate
Elimination of change parts avoids costs and delays
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14. ASTRRATM Automate Conveyors - And More
ASTRRA system automates more than conveyor rails! The system is modular, flexible and expandable to adjust other packaging equipment such as:
Labeller aggregate slides
Feed screws
Case packer - conveyor rails, lanes and flap plate positions
Any screw or slide adjustment
We welcome opportunities to configure custom ASTRRA actuator system to meet your requirements!
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15. ASTRRATM Getting Started
How do I get started?
What you need to do:
Provide a line layout
Have the willingness to embrace the culture of change
What A. S. Thomas will provide:
Proved a macro design
After your acceptance of the macro design AST will perform an engineering phase
Provide detailed components specification
AST will work with you to develop an implementation schedule.
ASTRRA can be installed in phases or all at once.
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16. ASTRRATM The Future of Automation - Available Today
ASTRRA makes it easy to upgrade your packaging line to gain the benefits of manufacturing automation:
Improved worker safety
Strengthened process discipline
Enhanced repeatability and flexibility
Increased uptime and production throughput
Ask yourself :
Is your company ready to become a world-class packaging facility that will lead the way for others to try and catch?
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