FEATURE LINEAR MOTION
With both variable pitch and speed forming the crux of the new machine, Maga Active turned to Rockwell Automation’s iTrak Intelligent Track Systems which offers multiple movers that can traverse a track independently of each other
the next step. Each station has three levels – corresponding to the component parts (base, silicone seal and cover) – and servos are used to move the parts from one level to the next depending on the operation being undertaken. The iTRAK system is part of an
DEVELOPING A
STATE-OF-THE-ART ASSEMBLY SOLUTION
During the development of a new irrigation-dripper
assembly machine, Rockwell Automation’s iTrak Intelligent Track System was chosen in order to reduce its size while improving performance levels
A
s a specialist in the design, build and automation of assembly machines
and lines, Maga Active was approached by a customer in Greece to develop a new machine for the automated assembly of insertion and drilling systems for drippers for agricultural irrigation lines. The new solution was to replace an existing fixed- pitch assembly system with a much more compact, variable-pitch machine, based around the use of high-speed servo systems and cameras for quality control. There were, however, a number of
challenges. Although shop floor space was limited, there was a need for greater throughput and product flexibility, plus accuracy was essential to precisely place various small and sometimes flexible components. Complete integration was also needed with the line’s vision system, which monitored the in-line and end-of-line product quality. With both variable pitch and speed
forming the crux of the new machine, Maga Active turned to Rockwell Automation’s iTrak Intelligent Track System. This, the company explains, offers multiple movers that can traverse a track independently of each other.
THE SOLUTION The iTRAK solution deployed by Maga
12 SEPTEMBER 2020 | DESIGN SOLUTIONS
Active is comprised of independently controlled movers running on straight and curved paths, removing the limitations of fixed-pitch systems. Combining linear and rotary motion results in a flexible, fully integrated, solution that can increase production throughput, and reduce maintenance and overall machine size. The new machine has ten work
stations along the iTRAK, some of which undertake sub-assembly operations, while others carry out inspection of the assembly operation using high- resolution cameras which sort them as pass/fail. The last working station on the track ejects the drippers into good/reject boxes. Each iTRAK mover
carries eight products in dedicated assembly jigs - a per-batch product count which immediately ramps up the production rate compared to the incumbent solution. As the mover presents each batch at the individual assembly station, various operations are undertaken to add components or orientate the assembly ready for
/ DESIGNSOLUTIONS
Integrated Architecture solution which is used to both actuate and control the majority of the machine’s primary functions. At the heart of the automation infrastructure is an Allen-Bradley CompactLogix programmable automation controller (PAC) working in conjunction with an Allen-Bradley PanelView Plus 7 operator interface. The machine deploys a number of Allen-Bradley Kinetix 350 servo drives to control Allen-Bradley TL-Series Electric Cylinders which undertake the Z axis movement between the three levels at each assembly station.
INCREASING THROUGHPUT Yehuda Duenyas, CEO of Maga Active commented: “With this new system we can achieve a throughput of 180-205 pieces per minute – far more than the older system it is replacing. The next machine will target 220-230 ppm.” As each ITRAK operates independently,
there is no weak link caused by long dwell times that would prevent the other assembly jigs traversing quickly between stations when their operations are complete. Of additional benefit, the iTRAK movers can travel at speeds up to 5m/s while still maintaining an accuracy of up to 0.5mm; and the new machine’s footprint is 40% smaller than the machine it replaces. “We have been able to deliver a
The new assembly solution offers significant performance benefits while taking up less space
state-of-the-art assembly solution that not only offers significant performance benefits, but also takes up less valuable real estate,” Duenyas stated. “The Integrated Architecture solution and iTRAK, with its outstanding performance, functionality and reduced footprint, will be used as a basis for future Maga Active machines.”
Rockwell Automation
www.rockwellautomation.com
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