Customer Challenge

Denison-Fungi-Pen-Case-Study-2.jpgDenison Pharmaceuticals asked RT Engineering Corporation for a quotation to modify an existing indexing machine to manufacture Fungi Nail Pen assemblies. The existing machine currently has a 12 station indexer, guarding, PLC, and pneumatic valves. RT will use as much of the existing components as possible to upgrade the machine to assemble the pens. The following changes will be made to the existing machine:

  • Disassembly existing machine as required
  • Modify rotary dial table to accommodate 12 new nests for holding the two size pens (2-up nest)
  • Estimated throughput 40 - 50 complete pen assemblies per minute
  • Update/add guarding for manually loading parts
  • Update safety monitoring circuit including light curtain and part present sensors to stations. The use of a light curtain will provide clear access for the operators to place the pen parts in the tooling nests. Once the last part is placed by the operator and the light curtain is clear, the dial table will index automatically.
    If the light curtain is broken by the operators,
    the dial table motion will stop.
  • Add pneumatic actuators and support brackets to assemble/press components together, two sets of tooling will be supplied for each pen size
  • Replace the PLC and generate new logic/code to run the assembly process
  • Provide brackets and control interface for fluid dispensing equipment

RT Engineering's Solution

Denison-Fungi-Pen-Case-Study.jpgRT Engineering proposes to design, build, program and test a machine that assembles three parts of a pen assembly.  All intellectual property will transfer to the customer upon final payment unless otherwise noted.

The assembly process will be based on the following sequence:

  • Operator #1 will place two pen bodies into the dial table nests. Pen bodies should be the same size/type. 
  • Rotary table indexes to fill station. Fill pump provided by Denison, RT to provide a control signal to turn pump on/off and brackets for supporting pump tubing/nozzles (2-up per pen size).  Nozzle position adjustment and “pens in place” sensors will also be included in the design to avoid liquid dispensing with pen present.
  • After the fill is complete, rotary table indexes, operator #2 loads two brush plugs into the pen bodies
  • Rotary table indexes, two brush plugs are pushed all the way into the bodies by pneumatic actuator. Tooling will be supplied for two brush plug sizes
  • Rotary table indexes. Operator #3 (this step may be handled by operator #2) will place two clear covers on the pen bodies.
  • Rotary table indexes to cap press station. Two caps are pressed in place.  Tooling will be supplied for two cap sizes. 
  • Rotary table indexes, operator #3 removes the two completed pen assemblies.
  • Rotary table indexes to operator station # 1 and cycle repeats.

The Result

  • Production increase of 30-40% over semi-manual operation for two product types
  • Eliminate operator manual/repetitive tasks
  • Improved product quality by automating key assembly operations
  • Improved safety and updated electrical control standards

To find out how performance monitoring systems could help your business, please contact RT Engineering today to learn how we can improve your company’s manufacturing processes.

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