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

2. 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

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

4. 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

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

6. 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

7. 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

8. 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

9. 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.

10. 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.

11. 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

12. Dispenser

13. 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

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

15. Outlook of the whole system
Dispenser System
Turntable

16. Filling of Epoxy
Epoxy Container
Tank
Dispenser Valve Unit

17. Dispenser valve unit
Cylinder

18. Closing of Hole
Opening of Hole

19. Epoxy Output
Pressure
Epoxy Injector
(Changeable)

20. Turntable Rotate

21. Our Prototype

22. Our Prototype

23. 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

24. 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

25. 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.

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

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

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

29. 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.

30. Sequence

31. PLC I/O diagram

32. Circuit Diagram

33. 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

34. 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

35. 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

36. 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

37. 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

38. 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

39. 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

40. 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

41. 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

42. Automatic Epoxy Dispensing Machine

43. The End
Thank you!

44. Question and Answer