Mechanical design and complete project management for a production line in China
In the context of high-speed production lines, quality control can no longer be a random or manual operation: it must be automatic, reliable and perfectly integrated into the production flow.
For this project I developed a analysis and quality control machine for wire spools, intended to operate inline downstream of an existing winding machine, for a production plant located in China.
From the very early stages, the design had to take into account not only the required performance, but also the fact that the machine would be installed and put into production abroad, in a high-productivity industrial context, where reliability, repeatability and ease of integration are fundamental.
Integration on existing line and operational flow
The machine was designed to integrate directly with the customer's existing roller conveyor, without modifying the existing production layout.
The work cycle is completely automatic:
- picking up the reel from the roller conveyor
- high-dynamic vertical axis lifting
- locking by means of pneumatic self-centering chuck
- controlled rotation for visual analysis
- repositioning on the roller conveyor below
Following the analysis, the line continues towards a automatic junction, which addresses:
- the compliant coils towards the palletizer
- non-compliant coils to the reject line
It all happens online, without intermediate accumulations and without slowing down the production process, a fundamental aspect for a plant intended to work on large volumes.
Performance-oriented mechanical design
One of the most stringent constraints of the project was the cycle time:
about 2.5 seconds per reel, equal to approximately 24,000 reels per day for each line.
To reach these numbers it was necessary push the performance of the mechanics to the limit, in particular on the vertical movement axis.
The solution adopted includes:
- ultra-high-speed vertical linear axis
- ball screw sized for intensive cycles
- high-performance linear guides to ensure rigidity and repeatability
- optimized kinematics to reduce moving masses and inertia
A new one has been integrated on the axis pneumatic self-centering chuck, designed for:
- ensure a solid and repeatable grip of the coil
- compensate for any dimensional tolerances
- allow for stable rotation during the analysis phase
Structure, materials and finishes
The entire machine was built using:
- structural aluminum profiles
- aluminum casings
- black anodized components, as requested by the customer
The choice of materials and finishes was not only aesthetic, but functional to obtain:
- structural rigidity
- low weight
- ease of transport and installation
- reliability over time in an international production context
Complete project management
This project was followed end-to-end, dealing directly with:
- complete mechanical design
- definition of kinematic architectures
- sizing of axes and critical components
- procurement and ordering of all materials
- management of mechanical processes and treatments
- assembly and final integration on the line
An approach that allows you to maintain technical control of the project at every stage, reducing unforeseen events, downtime and integration problems.
