Epoxy Dispenser Machine

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Epoxy Dispenser Machine

• Dispenser Part

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Design Objectives

1. To increase the productivity
2. To improve the quality of products
3. To simplify human work by automatic control

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Design Considerations

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

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Marketing Products
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Design 1

• Specification of Design 1
• Three dispensing heads
• Easy to clean through one main channel
• Simple to just fill one mixing tank

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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

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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

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Design 2

• ?
• The flow of epoxy may not be easy without the
  sliding angle
• The rivet pattern will be loosened by frequent
  use.

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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

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Operation

• ?Mixing of resin and hardener in a tank
• ?Pouring the epoxy into the rubber tank
• ?Control the PLC to open the valve
• ?Appropriate amount of epoxy is ejected to fill
  the coil

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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

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Epoxy Dispenser Machine

• X-Y table Part

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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

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Available Product on the market

• Conveyor
• x-y table in Lathe machine

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Comparison of the products

• Conveyor
• -lower cost
• -suitable for continuous process
• -using servo-motor and controlled by PLC
• -inflexible for different kinds of transformers

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Conveyor cost estimation
Model No. Bed Width Belt Width Weight Price Ea.
BMV-18 19" 18" 260 lbs. US1323
436 lbs. US1550
BMV-24 25" 24" 296 lbs. US1410
510 lbs. US1675
http//www.materialflow.com/Low_Profile_Mini_Belt_
Conveyors.htmRLP
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• 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

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X-Y table cost estimation

• MICROLUX X-Y TABLE ATTACHMENT
• Item Number 82389
• List Price US129.95
• 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?Merchant
IDRET01229ActionCatalogTypeProductID82389
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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

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X-Y table and PLCestimated cost

• X-y table 3000
• PLC 2000
• Profile 200/each

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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

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Working Procedure-1
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Working Procedure-2
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Working Procedure-3
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Working Procedure-4
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Working Procedure-5
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Working Procedure-6
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Working Procedure-7
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Working Procedure-8
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Working Procedure-9
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Working Procedure-10
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Working Procedure-11
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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.

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Preparation work for fixture

• Install the fixture for the desired type of
  transformer onto the x-y table
• Place the transformers on the fixture

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Normal Operation Steps

• 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.

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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.

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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

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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.

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Specification estimation

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