| The following details some actual examples of systems which Capley Marker have implemented
New production line integrating six robot cells
Our client had worked on the development of a new aircraft engine an won the order to produce various parts of it. Unfortunately the parts were too big to fit on the existing investment casting plant and they needed to enlarge the capability of this line without affecting production. The parts were too big for conventional manual handling so a new conveyor system was needed along with larger robots.
We worked with the client and a conveyor company and developed a plan for the full production line which could be implemented in sections and joined together each time a cell was added. The implementation plan took three years to complete and was ready in time for the new engine production.
The system consisted of seven Modicon PLCs and six InTouch SCADA systems. An RFID system and the PLCs were used to track the part anywhere through the process. Six robot cells were used to process the moulds.
Each wax mould was identified with a bar code and this was read at the loading station SCADA. The barcode was used to find the appropriate recipe from a database and this was loaded to an RFID tag which remained with the mould throughout the casting process. The mould was transferred to a robot and the data on the tag determined have the part was processed by the robot. After processing the robot placed the part back on the conveyor system in a controlled environment.
A single robot cell was developed and proven off site. We then removed an existing plant cell and inserted the new robot cell. Although it took two months to remove and install the planning and implementation meant minimum effect on production. As each cell was implemented, additional conveyors were added to join cells and reduce the level of manual handling and a huge drop in scrap was subsequently noticed
The new system not only provided the facility to process larger parts but production throughput was doubled. Additional advantages were implemented; better safety systems to reduce operator injury and plant/product damage; less paperwork moving around with product; better traceability; less downtime; improved software maintenance.
The client was so impressed in the improvement of the control systems that we have been working there for the subsequent eight years on all their other processes including boilerclaves, vacuum furnaces, wax handling and acid etching systems.
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