Wax Line “Zone A” Robot Handling Cell
In January, 2011, Tech-Con Automation Inc. was awarded a contract from an automotive tier one supplier, to install and integrate three robot handling cells to support a new wax application process. The tier one supplier’s customer had implemented a new requirement for their chassis cradles. As of November, 2011, the internal surfaces of the cradles had to be coated with a paraffin based wax, for rust prevention. The project required Tech-Con to interface with three separate overhead conveyor lines, to handle cradles entering and exiting the wax application system.
Tech-Con Automation Inc. successfully installed, programmed and integrated the robot handling system, dubbed “Zone A”, on time, on budget, while supervising the synergy of several sub-contractors hired by the tier one supplier, to complete the entire project.
Heavy duty CDLR conveyors are used to transport large racks with e-coated cradles towards the wax line. With a positive location of the incoming full rack, guided by the CDLR conveyor motors and held in place by actuation arms, a robot at the infeed automatically unloads each cradle onto an overhead conveyor for the wax application system. After the wax application process, a second robot automatically unloads cradles from the wax line and loads shipping racks, designed specifically for transportation directly to the end customer.
Tech-Con designed and fabricated pneumatically actuated End-Of-Arm-Tools to handle three types of cradles and integrated an RFID system to track each cradle throughout the entire wax process. Occasional rejects detected within the wax system are automatically placed on a reject shuttle by the outfeed robot, for an operator to safely remove cradles without entering the guarded robot cell. Cranes with lift assists are installed to help operators remove rejected cradles from the reject shuttles and place them on push carts, specifically designed for disposal or rework as required.
Sub-panels with Flex I/O and Safety I/O were provided to communicate with the main line PLC for the tier one supplier’s plant. Fencing, guarding and safety sensors were installed to ensure the entire process is compliant with OHSA industrial regulations.
Upon completion of the project, the tier one plant operators were provided with detailed, intensive training to ensure a seamless transition of Tech-Con’s programming and integration team to the plant support staff.
