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SMT-3103
SMARTELL
Work Station Process&Introduction
1.Unibody safety needle hub loading→
Place the needle hub on the vibrator, which aligns the needle hub. The robotic arm then uniformly clamps and places the products into the slide slot. A fiber optic sensor checks each product for accuracy. Once all products are in place, a cylinder clamps the entire row of products onto the fixture strip. Another fiber optic sensor checks if all fixtures have products; if any are missing, they are pushed to an empty position for manual replenishment. (Note: Products must be free of burrs or flash, as burrs can cause jams in the vibrator and slide track.)
2.→missing hub pushing-out
After the needle hub is installed, the fiber optic is used to detect whether there are products on the fixture strip. If ther is a missing needle hub, the fixture strip will be pushed to the empty position for centralized processing by manual.
3.→needle hub pressing
when the needle hub is not in place, press the needle hub to a certain position to avoid affecting the needle loading and prevent falling off.
4.→ needle tube loadin
the needle tube loading is lifted by the needle tube and then scraped to the needle hub mold to fall down to the needlhub. After the needle is lifted, the direction is turned and enters the glue station.
5.→missing needle pushing out
After the needle tube is well installed, the fiber optic is used to detect whether there are needle tubes on the needle hub. If there is a missing needle tube, the tool strip will be pushed to the empty position for centralized processing by manual.
6.→applying epoxy resin glue
The glue application process uses a servo motor to drive two linear guides that move the glue disk. The disk drives the glue from the box, and a photoelectric sensor detects the presence of glue in the box. The amount of glue can be adjusted using a photoelectric switch. Before applying glue, the glue is poured into a storage tank. If the sensor detects a low level of glue, the pressure from a pneumatic system pushes the glue from the tank onto the box. If the box is empty, the touch screen will trigger an alarm.
7.→rubbing the needle 1
The needle tube is placed on the fixed plate and rotated by reciprocating rubbing through the cylinder, and the blade surface of the needle tube is placed on the positioning plate (Note: After the blade surface of the needle tube and the safety sheath are aligned and the angle is rubbed, the tolerance is within ±15 degrees)
8.→rubbing the needle 2
The needle tube is placed on the fixed surface and rotated by reciprocating cylinder, and the blade of the needle tube is placed on the positioning plate. (Note: After the blade of the needle tube and the needle cap are aligned and rubbed at an angle, the tolerance is within plus or minus 15 degrees)
9.→placing it in the drying oven for curing
The drying tunnel dries the glue. The drying oven consists of six heating sections, glass lamps, stainless steel heating wires, two control boxes, and a current display meter. The temperature controller ensures the temperature reaches the required level to achieve a solid bond. After drying, the product is inspected for blockage. (The drying oven has a temperature alarm function, which alerts if the temperature is not within the set range.)
10.→ cooling in the fixture
11.→ blockage inspecting, using a camera to detect the adhesive (CCD)
CCD detects glue. The camera is mounted on a moving slider, which is driven by a servo motor to move back and forth. This movement allows the camera to inspect the connection points between the needle tube and the blade for any excess glue. Any defective items are removed at the rejection station. A protective dust cover is placed over the camera to prevent damage from falling objects. (One camera)
12.→a camera to inspect the blade surface of the needle tube (CCD)
The needle tip is detected by the camera to check whether the needle tip edge is in the same direction. If there is a defective product, it will be removed from the rejection place. There is a protective dust cover at the camera to prevent anything from falling and damaging the camera. (One camera)
13.→ a camera to inspect burrs and inverted needles (CCD)
The camera is mounted on a moving slider, which is driven by a servo motor to move back and forth. This process checks the needle tube for burrs and inverted needles. Any defective items are removed at the rejection station. A protective dust cover is placed over the camera to prevent objects from falling and damaging it. (One camera)
14.→ siliconizing
feeding the silicone oil on both sides, and rotate it 180 degrees. When applying the oil, a blow-by device is installed inside, and the silicone oil is applied from bottom to top. A pressure gauge is installed, and the machine will automatically shut down if the pressure does not meet the standard. The oil extraction is pneumatic to avoid power issues that could cause fires. After applying the oil, remove the defective parts. (Note: Silicone oil is flammable, so the oil quality should be cleaned every 2-3 days, and the circuit should be regularly inspected for damage to prevent unnecessary losses.)
15.→ defective parts removing
Waste removal is a combination of image CCD and inspection block to remove waste. Waste removal is
composed of 24 cylinders, electromagnetic valves and waste removal head. First, odd numbers are removed, then even numbers are removed. When the unqualified products are removed, and then the needle cap is entered.
16.→needle cap loading
Detection：the detection is KEYENCE fiber optic detection, check whether there is a needle tube, and then send the signal to the needle cap loading station.
Loading：The upper cover is designed with a slide track, made of 304 stainless steel. It is equipped with an automatic lifting hopper that efficiently transfers materials to the material bin. The system uses Autonics induction detection to check for the presence of the needle cap before conveying it to the slide track for stirring. The front row of the needle cap features 24 cylinders, each paired with a 24 electromagnetic valve for independent control. The system detects needle shortages in the needle cap, and if needles are missing, the needle cap is not released to prevent waste and ensure a high qualification rate for the needle cap loading.
17.→needle cap pressing
To press the needle cap. Below the needle cap, there is a position to straighten it to prevent needle penetration. After pressing the needle cap, an optical fiber is used to check if each needle has a needle cap. If any are missing, the tooling is moved to an empty position for manual processing to prevent unsecured products from falling into the finished material bin.
18.→ missing cap pushing out
After the needle cap is put on the fixture, the optical fiber will detect whether there are products on the fixture. If there is no product, the fixture will be pushed to the empty position for centralized processing by manual before being put back into the buffer station.
19.→finished parts discharging
Before finished product discharging, there is a counting function (fiber optic counting), and then the products are uniformly delivered to the material storage.
After the finished material is discharged, the whole cycle is completed.
Work Station Process&Introduction
1.Unibody safety needle hub loading→
Place the needle hub on the vibrator, which aligns the needle hub. The robotic arm then uniformly clamps and places the products into the slide slot. A fiber optic sensor checks each product for accuracy. Once all products are in place, a cylinder clamps the entire row of products onto the fixture strip. Another fiber optic sensor checks if all fixtures have products; if any are missing, they are pushed to an empty position for manual replenishment. (Note: Products must be free of burrs or flash, as burrs can cause jams in the vibrator and slide track.)
2.→missing hub pushing-out
After the needle hub is installed, the fiber optic is used to detect whether there are products on the fixture strip. If ther is a missing needle hub, the fixture strip will be pushed to the empty position for centralized processing by manual.
3.→needle hub pressing
when the needle hub is not in place, press the needle hub to a certain position to avoid affecting the needle loading and prevent falling off.
4.→ needle tube loadin
the needle tube loading is lifted by the needle tube and then scraped to the needle hub mold to fall down to the needlhub. After the needle is lifted, the direction is turned and enters the glue station.
5.→missing needle pushing out
After the needle tube is well installed, the fiber optic is used to detect whether there are needle tubes on the needle hub. If there is a missing needle tube, the tool strip will be pushed to the empty position for centralized processing by manual.
6.→applying epoxy resin glue
The glue application process uses a servo motor to drive two linear guides that move the glue disk. The disk drives the glue from the box, and a photoelectric sensor detects the presence of glue in the box. The amount of glue can be adjusted using a photoelectric switch. Before applying glue, the glue is poured into a storage tank. If the sensor detects a low level of glue, the pressure from a pneumatic system pushes the glue from the tank onto the box. If the box is empty, the touch screen will trigger an alarm.
7.→rubbing the needle 1
The needle tube is placed on the fixed plate and rotated by reciprocating rubbing through the cylinder, and the blade surface of the needle tube is placed on the positioning plate (Note: After the blade surface of the needle tube and the safety sheath are aligned and the angle is rubbed, the tolerance is within ±15 degrees)
8.→rubbing the needle 2
The needle tube is placed on the fixed surface and rotated by reciprocating cylinder, and the blade of the needle tube is placed on the positioning plate. (Note: After the blade of the needle tube and the needle cap are aligned and rubbed at an angle, the tolerance is within plus or minus 15 degrees)
9.→placing it in the drying oven for curing
The drying tunnel dries the glue. The drying oven consists of six heating sections, glass lamps, stainless steel heating wires, two control boxes, and a current display meter. The temperature controller ensures the temperature reaches the required level to achieve a solid bond. After drying, the product is inspected for blockage. (The drying oven has a temperature alarm function, which alerts if the temperature is not within the set range.)
10.→ cooling in the fixture
11.→ blockage inspecting, using a camera to detect the adhesive (CCD)
CCD detects glue. The camera is mounted on a moving slider, which is driven by a servo motor to move back and forth. This movement allows the camera to inspect the connection points between the needle tube and the blade for any excess glue. Any defective items are removed at the rejection station. A protective dust cover is placed over the camera to prevent damage from falling objects. (One camera)
12.→a camera to inspect the blade surface of the needle tube (CCD)
The needle tip is detected by the camera to check whether the needle tip edge is in the same direction. If there is a defective product, it will be removed from the rejection place. There is a protective dust cover at the camera to prevent anything from falling and damaging the camera. (One camera)
13.→ a camera to inspect burrs and inverted needles (CCD)
The camera is mounted on a moving slider, which is driven by a servo motor to move back and forth. This process checks the needle tube for burrs and inverted needles. Any defective items are removed at the rejection station. A protective dust cover is placed over the camera to prevent objects from falling and damaging it. (One camera)
14.→ siliconizing
feeding the silicone oil on both sides, and rotate it 180 degrees. When applying the oil, a blow-by device is installed inside, and the silicone oil is applied from bottom to top. A pressure gauge is installed, and the machine will automatically shut down if the pressure does not meet the standard. The oil extraction is pneumatic to avoid power issues that could cause fires. After applying the oil, remove the defective parts. (Note: Silicone oil is flammable, so the oil quality should be cleaned every 2-3 days, and the circuit should be regularly inspected for damage to prevent unnecessary losses.)
15.→ defective parts removing
Waste removal is a combination of image CCD and inspection block to remove waste. Waste removal is
composed of 24 cylinders, electromagnetic valves and waste removal head. First, odd numbers are removed, then even numbers are removed. When the unqualified products are removed, and then the needle cap is entered.
16.→needle cap loading
Detection：the detection is KEYENCE fiber optic detection, check whether there is a needle tube, and then send the signal to the needle cap loading station.
Loading：The upper cover is designed with a slide track, made of 304 stainless steel. It is equipped with an automatic lifting hopper that efficiently transfers materials to the material bin. The system uses Autonics induction detection to check for the presence of the needle cap before conveying it to the slide track for stirring. The front row of the needle cap features 24 cylinders, each paired with a 24 electromagnetic valve for independent control. The system detects needle shortages in the needle cap, and if needles are missing, the needle cap is not released to prevent waste and ensure a high qualification rate for the needle cap loading.
17.→needle cap pressing
To press the needle cap. Below the needle cap, there is a position to straighten it to prevent needle penetration. After pressing the needle cap, an optical fiber is used to check if each needle has a needle cap. If any are missing, the tooling is moved to an empty position for manual processing to prevent unsecured products from falling into the finished material bin.
18.→ missing cap pushing out
After the needle cap is put on the fixture, the optical fiber will detect whether there are products on the fixture. If there is no product, the fixture will be pushed to the empty position for centralized processing by manual before being put back into the buffer station.
19.→finished parts discharging
Before finished product discharging, there is a counting function (fiber optic counting), and then the products are uniformly delivered to the material storage.
After the finished material is discharged, the whole cycle is completed.
