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Soap Pump Assembly Machine Retrofit
Health Science | Assembly
Automation Solution for the Hygiene Industry
A manufacturer in the hygiene industry with expanding operations had a soap pump assembly machine capable of forming one type of pump, and they were interested in upgrading it to produce pumps in three different configurations. Because of the machine's modular design, TCA was able to perform a retrofit and upgrade it to handle more sophisticated operations.
The new, more complex, assembly machine consists of a 16 station mechanical indexer with two build nests per station. Operated using an Automation Direct operator interface with a data logging PLC, parts nests are built on a 1" thick, 60" diameter dial table. The components move through each of the 16 stations for assembly and bonding, alternating with inspection and testing, throughout the entire cycle. Safety features include floor mounted perimeter guarding with nine vertical hinged doors.
TCA's engineering team successfully designed the retrofit to effectively handle multiple soap pump configurations with minimal changeover. Our technicians disassembled the existing machine, reassembled it with new components we had fabricated in-house, and then adjusted all the electronics and wiring. All operations were fully tested before delivery to the customer location, where our technicians were on hand for the installation, start-up, and training.
Highlights
Project Description
We designed and manufactured this assembly machine retro-fit for a soap pump application, to be able to run 3 different parts.
Capabilities Applied / Processes
Mechanical Design
Design Assembly Machine Retro-Fit
Created 3-D Models
Manufactured in-house using our CAD/CAM equipment and capabilities
PLC Programming
HMI Design & Programming
Documentation
Hard Copy and CD-ROM Copy of Machine Manuals, Operating Procedures, Assembly Drawings, and Electrical and Pneumatic Schematics
Installation
Disassembly of Existing Machine
Reassembly of Machine w/ new Components
Wiring Installation
Start-Up
Warranty
-
1 Year Warranty up to 2,000 Hours Running Time
Assembly Machine Lay-Out
Consists of 16 Station Mechanical Indexer w/ 2 Build Nests Per Station:
Station 1 - Air Piston Bond, Inspect and Install
Station 2 - Spare Station
Station 3 - Foam Punch and Install
Station 4 - Foam Inspection
Station 5
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Spring Install and Cylinder Preassemble
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Lube and Install Station
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Off-Line Soap Piston Stem Nylon Mesh Bond
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Check Valve Install
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Soap Piston Stem and Moving Stem Preassemble and Install
Station 6 - Spare Station
Station 7 - Final Air Piston Snap
Station 8 - Gasket Punch and Install
Station 9 - Seat Gasket, Air Piston Flap Leak test
Station 10 - Soap Piston Moving Flap Leak test
Station 11 - Gasket Leak Test
Station 12 - Gasket Inspection Station
Station 13 - Laser mark
Station 14 - Spare Station
Station 15 - Cap Install, Part Unload/Reject
Station 16 - Nest Check for No Parts
Features
Designed to Assemble Three Different Configurations
Floor Mounted Perimeter Guarding w/ 9 vertical Hinged Doors
1" Thick Dial Table x Ø60"
Automation Direct Operator Interface with Data Logging
Allen Bradley SLC 5/04 PLC
Overall Lead Time
22 weeks
Overall System Dimensions
20 ft X 30 ft