Labotek Case Study: Conveyors for Part Separation

Labotek were tasked by a Tier 1 automotive supplier, to develop a conveyor system to separate left and right variants of plastic parts, created in a family tool.

The ethos at Labotek GB is to find a solution to challenges that our customers face each day. Each challenge is unique, and can encompass a wide range of criteria from conveying/drying/blending of polymers; to handling the finished product efficiently and accurately; to closing the loop with regrinding production waste and rejects to feedback into the process reliably.

Project:

Conveying products efficiently and accurately, using DynaCon Conveyors.

Challenge:

• A Tier 1 automotive supplier, produces a left and right variant of a part in a family tool. However, the parts need to be supplied separately to a designated assembly area directly on the production line of high-end automotive manufacture.
• Any errors in supplying the correct parts to the designated area may result in a line stoppage.
• If so, the supplier would receive a non-conformality of supply notice and risk penalties being incurred. Any proposed solution to reduce this risk would need to fit within the tight confines of the existing mould shop layout, take into consideration the layout of the existing tooling and be as cost-effective as possible.
• Any proposed solution to reduce this risk would need to fit within the tight confines of the existing mould shop layout, take into consideration the layout of the existing tooling and be as cost-effective as possible.

Solution:

To achieve the maximum effect, it was decided that the separation should be done as early as possible in the production process.

By utilising the existing Cartesian Robot, which was re-program so that the “Left hand” parts were deposited at a high level on a new conveyor set at 90° to the moulding machine and the “Right Hand” parts at a low level, onto an existing conveyor running towards the end of the machine.

Due to its modular nature, the customer selected a bespoke DynaCon swan neck conveyor, for the new conveyor requirement.

As the modular design allowed the conveyor to be constructed to provide a high-level section for the robot to deposit the parts on to, to be then conveyed to the low-level operator station.

All within a very short overall length of < 1.9m, to leave sufficient space for the operator station.

Result:

Since the installation of the new conveyor, all subsequent orders have been delivered with a 100% accuracy record. The working environment for the operators has improved due to the reduction of the stress surrounding the risk of making a mistake. As such productivity has improved.

A simple solution well executed.

To find out about the full range of Labotek’s ancillary equipment, and how you could benefit from their services, visit the Labotek website.

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