Operation of Machine
Sub-Assemblies Introduction
1. Outer Carton Assembly with Picture Frame
1.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Outer Carton Magazine with
Picture Frame
1.2 Outer Carton Assembly Operation
-
The shippers are loaded manually onto the magazine, which is equipped with a chain drive and motor for controlled carton feeding.
-
The magazine and picture frame assembly are provided with a sensor and photoelectric sensor to ensure the presence of shippers and to detect the carton level, confirming that sufficient cartons are available in the magazine.
-
The picture frame assembly is mounted to the magazine and is used to support, guide, and align the shippers during loading and feeding as they move toward the plucking and erection station.
-
The height of the picture frame assembly is adjustable according to the shipper height by setting the required counter value.
-
The width of the picture frame assembly is adjustable using knobs and levers to accommodate different carton sizes.
-
When the main drive moves forward, the leading magazine indexes accordingly, and the plucker erects the outer carton.
-
A locking cylinder retains the erected carton shape by applying force at the carton corners, while proper adjustment of the picture frame assembly ensures smooth carton movement and prevents misalignment or jamming during operation.
1.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment, including the magazine and picture frame assembly.
-
Always remove power and wait at least 30 seconds before connecting or disconnecting any internal harnesses associated with the magazine or picture frame assembly. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static-sensitive devices used in the magazine and picture frame assembly.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service, or tamper with the equipment, including the magazine and picture frame assembly.
-
DO NOT connect or disconnect any digital or analogue components of the magazine or picture frame assembly while power is connected, as damage may result.
-
Click the below Maintenance Schedule for the Magazine and Picture Frame Assembly.
1.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
1.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. It involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills for the equipment, including the magazine and picture frame assembly.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems, assemblies, or equipment are affected—such as the magazine or picture frame assembly—and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below for troubleshooting related to the magazine and picture frame assembly.
1.6 Spare Parts
Note: Click on the Description for details about Spare parts
Long Linear Bearing LM25L-A
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
2
1.
2.
4.
GRLA-M5-QS-6-D
VUVS_LK20_B52_D_G18_1C1_p
2
2
1
1
UC-1/8
Pneumatic Cylinder_DFM-12-50-P-A-GF
NTN F-UC203D1_LP03
Darshana Knob Handle DKCSQS-25M525
6.
7.
8.
9.
2
1
1
2
1
2. Plucker For Outer Carton With Flap Opener Assembly
2.1. 3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
flap opener Assembly
Outer Carton Plucker Assembly
2.2.Plucker for outer carton Assembly Operation
-
After feeding the outer carton by the magazine the plucker will pluck the carton with the help of vaccum and the plucker performs horizontal movement through a servo-controlled mechanism to ensure precise positioning and smooth operation.
-
After plucking the locking cylinder will hit the carton for retaining its shape and locking the position . Then a photoelectric sensor is mounted for checking the presence of carton over main drive.
-
After that the main drive will indexed to forward then it have the flap opener assembly . With the help of multiple pneumatic cylinders it opens the major and minor flaps of the carton.
-
There is a hopper for a specific recipe which helps to insert the inner cartons inside the outer carton.
2.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
2.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
2.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
2.6 Spare Parts
Note: Click on the Description for details about Spare parts
Suction Cups VASB-55-1/4
Solenoid Valve_VUVS-LK20-B52-D-G18-1C1-S
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
2
1
1.
1
2.
Pneumatic Cylinder_DSNU-8-50-P-A
1
1
4.
Pneumatic Cylinder_DSNU-16-185-PPV-A
DGC 32-300 Cylinder
1
DSBC-32-400-PPVA-N3 Cylinder
Hiwin HGH-20HC Carriage
6.
7.
1
8.
SBPL-25HV
1
3. Inner Carton Magazine Assembly
3.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Inner Carton Magazine
-
Inner Carton magazine is used to feed the inner carton for a particular recipe which requires 4 inner cartons to be inserted inside the outer carton.
-
It consists of one induction motor for feeding the cartons to the Plucker and a photo electric sensor for checking the level of carton in the magazine.
3.2.Inner Carton Assembly Operation
3.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
3.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
3.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
3.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
2
1
1.
3
2.
3
3
2
4.
2
4. Plucker For Inner Carton Assembly
4.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Plucker for inner carton
4.2. Plucker for Inner Carton Assembly Operation
-
Plucker for inner carton is used to pluck the inner carton from magazine and form the shape with the help of locking cylinder
-
With the help of pneumatic cylinders and vaccum cups the cartons are erected and there is a photo electric sensor for detecting the carton presence over the cleated conveyor
4.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
4.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
4.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
4.6 Spare Parts
Note: Click on the Description for details about Spare parts
Suction Cups VASB-55-1/4
WRONG
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
2
1
1.
1
2.
1
1
1
4.
2
2
1
DSBC-32-400-PPVA-N3 Cylinder
Hiwin HGH-20HC Carriage
6.
7.
1
8.
SBPL-25HV
1
5. Cleated Conveyor Assembly ( Main Drive for Inner Carton ).
4.1.3D Model
-
Product Contact Parts - PLA
-
Product Non-Contact Parts - MS, RAL 7045
Cleated Conveyor
5.2. Cleated conveyor Assembly Operation
-
Cleated conveyor is used for building collation of 4 cartons for a specific recipe
-
It consist of one servo motor which is used for indexing . After inner carton pucker operation the cartons are placed over the cleated conveyor and a photo electric sensor is used to detect the presence of cartons and another is used for checking whether the cartons are picked by the gantry.
5.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
5.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
5.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
5.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
6. Gantry Assembly For Inner Cartons
6.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Gantry Assembly
-
Gantry assembly is used for pick and place of inner cartons in outer carton with the help of hopper
-
It consists of 2 servo motors for X & Z axis movement and 3 pneumatic cylinders for picking the cartons and 2 proximity sensors for each servo homing.
6.2. Gantry Assembly Operation
6.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
6.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
6.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
6.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
2
1
1.
3
2.
3
2
4.
2
7. Main Drive Assembly
7.1.3D Model
-
Product Contact Parts - NYLON, SS304
-
Product Non-Contact Parts - MS, RAL 7045
Main Drive Assembly
7.2. Main Drive Assembly Operation
-
Main drive assembly is used for carrying the cartons for filling the satchets and for tucking assembly
-
It consist of 2 servo motors for adjusting the width between 2 dock which is used to hold the carton throughout the process and it changes its width according to recipe.It also consist of an Encoder for recording its position
-
Also it have a photo electric sensor for checking the presence of carton over the main drive , The it have a barcode scanner to detect the code is according to the recipe or not,After that it goes to filling station where the satchets are filled then it moves forward and 3 photo electric sensors are mounted before tucking assembly to detect the major and minor flaps , Then after the tucking assembly another 3 photoelectric sensors are mounted for verifying whether the flaps are open or not. At last 2 proximity sensors are located for both servo's homing
7.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
7.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
7.6 Spare Parts
Note: Click on the Description for details about Spare parts
HIWIN HGH-15CA CARRIAGE
LDK TP-F 206 HSG 4-BOLT FLANGE WITH CC COVER
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
1
2.
1
4.
NTN UC206-30
AT 10 DRIVE BELT
Encoder_DFS60B-S4PC10000
keyless bushings
Bearing
LDK TP-F 206 Hsg 4-Bolt Flange
AT10 DRIVE BELT
Metric Pulleys AT10, 32mm belt
NTN 6006ZZ
30205 SKF Taper Roller Bearing
Drive Shaft
Drive Sleeve
NTN 2008 Flanged bearing
NTN UC210-50
LDK TP-F 210 Hsg 4-Bolt Flange
Proxy Sensor
SUPPORT PLATE-1
SUPPORT PLATE-2
Flight Base
Flight Base 2
Cylinder ADN-12-120
Darshana Knob Handle DKCS-50M1030
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
5
5
5
1
2
7.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
8. Infeed Assembly
8.1.3D Model
-
Product Contact Parts - PU, SS304
-
Product Non-Contact Parts - MS, RAL 7045
Infeed Assembly
8.2. Infeed Assembly Operation
-
The Infeed assembly is used for placing sachets on the conveyor, from where they are picked by the robot for further processing.
-
It consists of a vision detection system at the start of the conveyor to verify the presence, orientation, and correctness of the satchets before they proceed.
-
Sachets are then picked by the robot based on the vision detection guidance.
-
The assembly also consists of four rejection bins: three bins located near each robot station for immediate rejection of incorrectly placed or faulty sachets, and one bin at the end of the conveyor for sachets that are not detected or missed during processing.
-
The conveyor transports the sachets from the Upstream to the robot pick region and then towards the rejection if not detected.
8.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
8.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
8.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
8.6 Spare Parts
Note: Click on the Description for details about Spare parts
NTN 6904LLU
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
Zn.Pl Circlip A Type Dia. 20
1
2
2
NTN 6001ZZ
NTN 6201ZZ
NTN UC206-30
V-GUIDE BELT
Bonfiglioli Motor BE 80B 4
Rotary Incremental Encoders
Encoder cable, M12, 8 pin, 20m
PE Sensor
Driven Roller
Drive Roller
6.
7.
8.
9.
10.
11.
12.
2
1
1
1
1
1
1
1
1
9. Flap Folding Assembly
9.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Flap Folding Assembly
9.2. Flap Folding Assembly Operation
-
The Flap Folding Assembly is used for folding and tucking the carton flaps after the satchets and booklet have been placed inside the carton.
-
It consists of multiple cylinders and mechanisms that perform the folding and tucking operations during each index of the carton.
-
The assembly also consists of three photoelectric sensors to detect the two minor flaps and one major flap to verify whether the carton is properly folded or defective.
-
Based on the sensor feedback, cartons are either rejected if the flaps are not correctly folded, or transferred to the lifting assembly for further processing.
9.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
9.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
9.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
9.6 Spare Parts
Note: Click on the Description for details about Spare parts
Pneumatic Cylinder_MGPL-16-100AZ-M9PSAPC
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
Pneumatic Cylinder_MGPL-16-100Z-M9B
Pneumatic Cylinder_DRVS-12-90-P
DSR-25-180-P
Hiwin HGW-20CC Carriage
SKF Deep Groove Ball Bearing W 6204-2Z
DRVS-12-90-P--(45)
SKF Deep Groove Ball Bearing 6004-2Z
SMC Cylinder
Diffuse sensors GTB6-P4231
1
1
1
1
1
1
1
1
1
1
6.
7.
8.
9.
10.
10. Booklet Barcode Scanner & Magazine Assembly
10.1.3D Model
-
Product Contact Parts - SS304,
-
Product Non-Contact Parts - MS, RAL 7045
Booklet barcode scanner & Magazine Assembly
10.2. Booklet barcode scanner & Magazine Assembly Operation
-
The Booklet, Barcode, and Magazine Assembly is used for placing small booklets with asymmetrical cardcodes into the cartons.
-
It consists of a magazine that holds the booklets, which are plucked by a vacuum-based mechanism. The plucking is assisted by servo and pneumatic systems for precise handling.
-
Each booklet is then scanned by a barcode reader to verify its validity and orientation.
-
If the booklet is valid and correctly oriented, it is placed into the carton through the hopper. If the booklet is invalid or incorrectly oriented, it is directed to the rejection bin.
-
Incase of booklet not being placed in carton, the carton will be rejected at the end of the main drive assembly.
10.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
10.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
10.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
10.6 Spare Parts
Note: Click on the Description for details about Spare parts
SMC Vacuum Generator ZK2B10K5RW-06
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
1.
2.
4.
FSGA 22 SI-55 G1/8-AG
SMC Silencer AN15-C08
Pneumatic Cylinder_ADN – 12-25-A-P-A-Q
linier bearing
UCP 201 Pilllow Block Bearing
NTN 6205LLU
Diffuse sensors GTB6-P4231
1
1
1
1
1
1
1
1
6.
7.
8.
1
11. Carton Barcode Scanner Assembly
11.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Carton barcode scanner Assembly
11.2. Carton barcode scanner Assembly Operation
The Carton Barcode Scanner is used to scan the barcode located on the upper edge of the carton’s major flap to verify its validity and printing quality.
Once the carton is placed and formed in the carton erector assembly, it passes under the barcode scanner. The assembly also includes a photoelectric (PE) sensor to detect the presence of the carton at that index.
-
If both the PE sensor and the barcode scanner signals are high, the carton is considered acceptable.
-
If the PE sensor is not high, the carton is not detected, and the robot will not place a booklet or satchet at that index/bucket.
-
If the barcode scanner signal is not high but the PE sensor is high, the carton is physically placed, but it will be rejected later at the end of the main drive assembly through the flap folding assembly rejection system.
11.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
11.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
11.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
11.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
2
1
1.
3
2.
3
2
4.
2
12. Robot Pick and Place With Pick Head Assembly
12.1.3D Model
-
Product Contact Parts -
-
Product Non-Contact Parts - MS, RAL 7045
Robot Pick and Place scanner Assembly
12.2. Robot Pick and Place Assembly Operation
-
The Robot Pick and Place Assembly is used for picking sachets from the infeed conveyor and placing them into cartons on the main drive assembly.
-
Sachets are first detected at the start of the infeed conveyor by the vision detection system, which verifies their presence and orientation.
-
The Quattro Omron robot then picks the sachet from the conveyor using a vacuum-based pick head. The pick head is equipped with a photoelectric (PE) sensor to confirm whether the sachet has been successfully picked.
-
Once the sachet is detected as picked, the robot accurately places it into the carton on the main drive assembly.
-
If a sachet is missing, not picked, or incorrectly oriented, it is not placed, ensuring only valid sachets are deposited into the cartons
12.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
12.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
12.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
12.6 Spare Parts
Note: Click on the Description for details about Spare parts
Bellows suction cup (oval) SPOB1f 80x35 SI-55 G1/4-IG
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
2
1
1.
2.
1
2
4.
2
SMC Vacuum Generator ZK2B10K5RW-06
Vacuum filter VAF-PK-4
QS-1/4-6
Solenoid Valve_ZK2-ZSVB-A
13. Vision System Assembly
13.1.3D Model
-
Product Contact Parts -
-
Product Non-Contact Parts - MS, RAL 7045
Vision System Assembly
-
The Vision System is used for detecting sachets on the infeed conveyor and providing the instance information to the robot for accurate picking.
-
It consists of a camera that performs edge detection to determine the exact position and orientation of the sachet. The position instance is calculated based on encoder feedback from the infeed assembly.
-
The camera is enclosed in a protective guard to ensure safety and prevent damage. Additionally, the system includes two lights for illumination to provide consistent and clear imaging for reliable detection.
-
The vision system ensures that the robot receives precise pick coordinates, allowing it to pick sachets accurately and place them into the cartons on the main drive assembly.
13.2. Vision System Assembly Operation
13.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
13.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
13.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
13.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
2
1
1.
3
2.
3
2
4.
2
14. Outfeed Conveyor Assembly
14.1.3D Model
-
Product Contact Parts - SS304, PU
-
Product Non-Contact Parts - MS, RAL 7045
Outfeed Conveyor Assembly
14.2. Outfeed Conveyor Assembly Operation
-
The Outfeed Conveyor is used for transporting cartons from the main drive assembly to the next machine or to the rejection system.
-
Cartons that are accepted after all inspections are carried forward to the downstream machine for further processing.
-
Cartons that are rejected due to flap misalignment, invalid booklet, barcode errors, or other quality issues are diverted by a pneumatic cylinder into the rejection bin.
-
The outfeed conveyor ensures a smooth and controlled transfer of cartons while maintaining separation between accepted and rejected cartons.
14.3. Maintenance
Important Precautions:
READ this manual before operating or servicing this equipment.
-
Always remove power and wait at least 30 seconds before connecting/disconnecting any internal harnesses. Failure to observe these precautions may result in damage to or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
-
SAVE this manual for future reference.
-
DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
-
DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Click the below Maintenance Schedule for magazine assembly.
14.4.Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document.
14.5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
Refer to the below about the Troubleshooting.
14.6 Spare Parts
Note: Click on the Description for details about Spare parts
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
2
1
1.
3
2.
3
2
4.
2