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MU 7 Mak Fu Shun Kong Yau Choi Lee Man Kit Poon San On Zen

YKK Project: Automatic adhesive machine. MU 7 Mak Fu Shun Kong Yau Choi Lee Man Kit Poon San On Zen. Introduction. YKK Hong Kong Limited established in 1966. As a subsidiary of YKK Corporation. One of the biggest corporation in producing and selling zippers. Introduction.

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MU 7 Mak Fu Shun Kong Yau Choi Lee Man Kit Poon San On Zen

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  1. YKK Project: Automatic adhesive machine MU 7 Mak Fu Shun Kong Yau Choi Lee Man Kit Poon San On Zen

  2. Introduction • YKK Hong Kong Limited established in 1966. • As a subsidiary of YKK Corporation. • One of the biggest corporation in producing and selling zippers.

  3. Introduction • Co-operate with YKK Co. to design an extended automatic adhesive machine. Existed Automatic adhesive machine

  4. Introduction Our job is to design a machine to stick the other two sides. (More complicated) YKK Co. now can only stick the tape onto the middle region of the box. (Easier task)

  5. Initial Design 1 The cylinder with a plate to push the box forward. At this region, here are the 2 adhesive machines given from YKK, which are not shown to reduce complicated drawing. The result are like above, only half is attached!

  6. Initial Design 2 Each set has 2 cylinders, first the horizontal ones extends to touch the box.

  7. Initial design 2 Vincent

  8. Once the box press the senor, cylinder will push the box to the second conveyer. Therefore, the box can change the direction. Sensor

  9. Then the box will pass through the sticking machine.

  10. Initial Design 3 Eddie

  11. Initial design 3 smoother brush

  12. Initial design 4 By Jason

  13. Initial design 4

  14. Intermediate Design

  15. Step 1 : To push the box into conveyor

  16. Step 2 : Stick adhesive paper on the box

  17. Step 3 : Rotational cylinders press the adhesive paper firmly

  18. Final Step : Cylinders press adhesive paper firmly

  19. Different Size of boxes

  20. Final Design

  21. The different between new design and old design New Design Old Design

  22. Old Design New Design

  23. Working Mechanism

  24. Main support : Hold the upper support and adjust the height for different boxes size

  25. Parts : Cylinder Linear Bearing

  26. Upper Support : Hold the all the main part of adhesive machine and adjust the wide

  27. Cylinder and Linear bearings

  28. Hold all the main parts

  29. BOM • Two Adhesive machines • 9 Cylinders • 6 linear bearings • 22 Sensors • 1 PLC model • 1 Touch Panel • Long/Uncut Profiles, Cables…

  30. Planning of works • Profiles cutting & Surface finishing ~1.5 weeks (due to change of design) • Holes drilling ~5 days • Construction of frames ~2.5 days • Mounting parts for cylinders installed on frame ~2 weeks • PLC & Touch Panel Programming learning ~ 1.5 days • Simens PLC Programming Simulation and testing ~ 3 days • PLC programming drafting ~1.5 days • PLC programming design ~3 days • Touch Panel programming design ~2.5 days • Testing & Debugging on working condition of touch Panel connecting with PLC. ~2 days • Installation & connection of PLC, Touch Paneland solenoid valve using cables ~3 days (PLC & TP finished by 24 June.) • Website making ~1.5 weeks, continuously • Modification on the design ~1 week • Whole machine testing and debugging ~2 days

  31. Machining Machining

  32. Machining Workshop • Milling Machine- holes drilling- surface finishing • Sawing Machine-cutting Profiles

  33. Milling Machine • Increase the smoothness of the surface • Rotating speed • Cooling liquid

  34. Milling Machine • Drilling holes • Milling Surfaces

  35. Milling Machine • Drilling holes- Center Drill- corresponding dia Drill, E.g. 6 mm dia Drill (different sizes)- 26-mm dia Drill- Boring tool • Cautions

  36. Milling Machine • Milling Surfaces- Milling Cutter (different sizes) • Cautionsdo not mill deeply& too fast

  37. Milling Machine • Products

  38. Parts

  39. Sawing Machine • Cautions- adding cooling liquid Increase the smoothness of the surface- cutting error shortermilling surface

  40. NCM Workshop • Electro-Discharge Machine (EDM)- Wire Cut (the shaft is too hard) • Cautions- Flammable Liquid

  41. Difficulties in Machining • High Precision-squareness-same length • Some holes are too big to drill • Linear bearing shaft- too hard (strong steel) • Thread not matched - Straight Adaptor does not fit cylinder provided by YKK

  42. System Control • Pneumatics /Cylinders Connect to input devices Sensor Both Input & Output Connect to Touch Panel Connect to output devices Solenoid Valves

  43. Why use PLC? • Cost effective. • High stability and flexibility. • Can work under adverse environment. • Easy programming. • Plenty input and output addresses, moreover extendable.

  44. Input & Output addresses 24 Input Addresses (All used) 000: Touch Sensor 001: Retraction sensor of Long Cylinder. 002:Extension sensor of Long Cylinder. 003-010: Built-in sensors of Cylinders. 011: Big Box button. 100-107: Built-in sensors of Cylinders. 108-109:External Photoelectric Sensor. 110: Start Button 111:Reset Button 16 Output Addresses: (10 used) 1000-1100:Cylinders 1101: Blocking unit

  45. Input/Output Table for PLC

  46. PLC Programming

  47. Why use Touch Panel? • Can emulate buttons & switches easily. Reduce complication. • Can emulate lights. Check output status. • Shows the input & output status. Check the operating process. • Easy Programming. High efficiency.

  48. Touch Panel Programming Press Start button sensors triggers, machine works on itself.

  49. Status of Sensors & Cylinders LC: long cylinder RC: rotational cylinder BC: Brush cylinder boxes counter: use Sensor to sense the box, and add 1 each time.

  50. Testing Test on Touch Panel with PLC Test on PLC Program Test if PLC reacts exactly to the commands of Touch Panels. Use Dip-Switch to emulate the sensors and buttons.

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