Operation of Machine
Sub-Assemblies Introduction:
1. Magazine Assembly
1.1.3D Model
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Product Contact Parts - SS304
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Product Non-Contact Parts - MS, RAL 7045
Magazine
1.2.Magazine Assembly operation
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The shippers will be loaded manually on the magazine.
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Magazine is equipped with Pneumatic Cylinder. The magazine One sensor to Check the level of cartons .
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A plucker will pluck cartons with the help of vaccum cups .
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After picking one carton by the plucker magazine will come forward once with the help of cylinder.
1.3. 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.
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.
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.
1.6 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
2. Plucker Assembly
2.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Plucker Assembly
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.
2.2. Plucker Assembly operation
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Pneumatic plucker cylinder extracts a single carton from the magazine.
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Photoelectric sensor confirms carton presence at the plucker pick position.
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Carton erection is carried out using dedicated locking cylinders:
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Left-hand side (LHS) locking mechanism
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Right-hand side (RHS) locking mechanism
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Ensures proper carton squaring and dimensional stability.
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
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
2
1
1.
3
2.
3
2
4.
2
3. Tucking Assembly
3.1.3D Model
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Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Magazine
3.2. Tucking Assembly operation
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Closes the carton flaps after the product is placed inside the box.
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First closes the minor flaps, then closes the major flap.
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Uses pneumatic cylinders to fold the flaps.
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Works only when the carton is in the correct position.
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Receives a confirmation signal after the robot places the product.
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Ensures the carton is properly closed before moving forward.
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Sends the carton to the next station for flap checking.
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
2
4.
2
4. Main Drive Assembly
4.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Maindrive Assembly
4.2. Maindrive Assembly operation
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Moves the cartons through the machine.
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Driven by an induction motor with gearbox for smooth and controlled movement.
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Stops the carton at each station for operation.
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Starts and stops automatically as per machine sequence.
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Works only when the previous step is completed.
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Sends the carton forward to the next station.
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Transfers the carton to the outfeed conveyor at the end.
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
3.
5.
Description
Consumables
Essential
Recomended
Sr No.
2
1
1.
3
2.
3
2
4.
2
5. Infeed Conveyor Assembly
5.1.3D Model
Infeed Conveyor
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Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
5.2. Infeed Conveyor Assembly operation
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Feeds blisters into the cartoning machine.
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Driven by a servo motor for precise and controlled movement.
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Positions blisters accurately according to the selected SKU.
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Stops automatically when required number of blisters is not available.
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Works in synchronization with the main drive conveyor and robot.
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Equipped with sensors to detect blister presence.
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Ensures smooth and continuous product supply for loading operation.
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.
2
1
1.
3
2.
3
2
4.
2
6. Outfeed Conveyor Assembly
6.1.3D Model
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
Outfeed Assembly
6.2.Outfeed Assembly operation
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Transfers packed cartons out of the machine.
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Receives cartons after tucking and flap closing operation.
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Equipped with photoelectric sensors to detect carton presence.
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Includes a rejection mechanism at the outfeed station.
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If minor or major flaps are detected as open, the carton is rejected into the rejection bin.
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Properly closed cartons are conveyed forward for further handling
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. Robot Assembly
7.1.3D Model
Robot Assembly
-
Product Contact Parts - SS304
-
Product Non-Contact Parts - MS, RAL 7045
7.2.Robot Assembly operation
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Uses a FANUC CR-7iA robot for product loading.
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Picks the blister stack from the pick position.
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Places the blister stack accurately into the carton.
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Operates only after confirmation of:
-
Blister presence
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Correct stack height
-
Carton in position
-
Works in synchronization with the main drive conveyor.
-
Ensures precise, repeatable, and safe loading operation.
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.
7.5. 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.
7.6 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