Epoxy Dispenser Machine

Dispenser Part

Design Objectives

1. To increase the productivity

2. To improve the quality of products

3. To simplify human work by automatic control

Design Considerations

Easy to assembly Easy to clean Easy to have maintenance User friendly Economical Effective production

Marketing Products

5000桌上型雙液自動混合機

6000型

雙液自動混合機

7000型

雙液自動混合機

Design 1

Specification of Design 1:

•Three dispensing heads•Easy to clean through one main channel•Simple to just fill one mixing tank

Design 1

Use one tank then diversify three syringe heads to fill

Hard to maintain the same pressure and

flow amount of each head Imperfect product would be the result

Design 2

Specification of Design 2:

•Easy to assembly by rivet system•Easy to clean as using plastic bag to wrap the surface•Easy to disassembly by loosening the rivet for cleaning

Design 2

The flow of epoxy may not be easy without

the sliding angle The rivet pattern will be loosened by

frequent use.

Design 3

Specification of Design 3:

•Modification of Design 2•Easy flow for the epoxy with a sliding angle in the tank•Reliable screw system for easy assembly and disassembly

OperationMixing of resin and hardener in a tankPouring the epoxy into the rubber tank

Control the PLC to open the valveAppropriate amount of epoxy is

ejected to fill the coil

Cost Estimation Regulator/ Pressure gauge ~$155/pc Safety valve ~$100/pc Plastic tank ~$50/pc Surface tank (with cover and lock) ~$250/pc Screw ~$50/100pc Disposable syringe ~$125/100pc Rubber ring ~$50/25pc Stainless Steel ~$7/lb Gas cylinder ~$200/pc

Epoxy Dispenser Machine

X-Y table Part

X-Y table Objectives

Provide one degree of freedom Precise movement for dispensing Sensors detected the positions Afford a loading of supporting 9 largest

size transformers and the container Controlled by PLC

Available Product on the market

Conveyor x-y table in Lathe

machine

Comparison of the products Conveyor

-lower cost

-suitable for continuous process

-using servo-motor and controlled by PLC

-inflexible for different kinds of transformers

Conveyor cost estimationModel No.

Bed Width

Belt Width

Weight Price Ea.

BMV-18 19" 18" 260 lbs. US$1323

436 lbs. US$1550

BMV-24 25" 24" 296 lbs. US$1410

510 lbs. US$1675

http://www.materialflow.com/Low_Profile_Mini_Belt_Conveyors.htm#RLP

x-y table in the Lathe machine

-expensive

-using servo-motor and controlled by PLC

-suitable for all kinds of transformers by change the container

X-Y table cost estimation MICROLUX X-Y TABLE ATTACHMENT Item Number: 82389 List Price US$129.95 Specifications (inches): Table Size: 8-1/4 L x 2-3/4 D Overall Size: 10-1/2 L x 7-1/2 D x 1-11/16

H Base Size: 3-3/4 x 5-1/2 X Direction Travel: 5-1/4 Y Direction Travel: 1-3/4 Dial Graduations: .001; .050 per revolution

http://www.ares-server.com/Ares/Ares.asp?MerchantID=RET01229&Action=Catalog&Type=Product&ID=82389

Our Design similar to product 2

Upon the above comparison, we choose product 2.

-not for continuous process

-suitable for various types of transformers

-precise position controlling by using servo-motor and PLC

X-Y table and PLCestimated cost

X-y table ~$3000 PLC ~$2000 Profile ~$200/each

Maximum Loading

9 transformers for the largest one Total weight of transformer: 1.468kg X 9 pieces

=13.212 kg The largest volume filled with epoxy = 142.5 Total weight of epoxy filled into the space =

1.833 kg The weight of the fixture = 7.5kg Therefore, the predicted weight is about 22.545

kg

3cm

Working Procedure-1

Working Procedure-2

Working Procedure-3

Working Procedure-4

Working Procedure-5

Working Procedure-6

Working Procedure-7

Working Procedure-8

Working Procedure-9

Working Procedure-10

Working Procedure-11

Limitation of our design

Only two sizes of transformer would be prepared for the operation.

Translation of the transformers is needed.

Air bubble may be formed during the process.

Preparation work for fixture

Install the fixture for the desired type of transformer onto the x-y table

Place the transformers on the fixture

The fixture moves from the initial position

The fixture moves along the x-table designed to where to dispense

The valve would be opened by the signals given by PLC.

Normal Operation Steps

Normal Operation Steps

The epoxy will start to flow from the dispenser to fill the inner core of the transformers.

The PLC would give the signal to control the valve and stop the dispensing process.

Normal Operation Steps

Upon the dimensions of the fixtures, the fixture will move and stop several times to fill all transformers on the fixture with epoxy

Normal Operation Steps

After all transformers are filled, the fixture will move to the end of the x-table.

The transformers will then be available for the workers taking to the oven.

Specification estimation

Filling time: 30s / each transformer Cleaning time: 15 mins Setup time: 5 mins