AUTOMATION

32

“To be the chosen supplier for adhesive and sealant application systems. Based

on Quality, Reliability, and Performance.”Grunfeld Mission Statement

AUTOMATED A D H E S I V E D I S P E N S EAUTOMATED A D H E S I V E D I S P E N S E

The theories of adhesion

There can be many reasons for considering the automation of a bonding process.

When implemented successfully, the outcomes are always the same – better product, faster throughput, reduced waste and reduced cost.

How many times is a constraint discovered because a particular manufacturing process “can’t be done by just anyone”!?

How many times do bonded parts fail, because the operator applied the adhesive, went for a break and ‘got diverted’ on his return, assembling the parts some 15 minutes later than they should have been?

How many times has your production throughput been determined by the number of good operators that can correctly apply the adhesive or sealant?

How often do you wish that you could save time in your production process?

How much time is spent training and re-training production operators when a process failure results in scrapped parts?

Don’t only think of robots! Many of us conjure up in our minds, visions of bright orange robots dancing above the body shells of cars, applying hem flange sealant at breath-taking

speeds.

Whilst robotic systems have their place, there are often more appropriate systems of automation, that whilst not so fascinating to watch are fast, efficient and ultra-reliable.

The key objective is to improve the consistency of the finished product or sub assembly, to increase throughput and reduce costs.

Importance of processConsistencyOpen timeSpeed of application Reduction of labourIncrease of throughput Automation 54

Automated Adhesive Dispense

“Automated Dispense Systems for flat and 3D panel laminations, bonding SIPs, composite panels – X-Y Axis

gluing lines and full robotic applications.”

DESIGNBUILD &INTEGRATE 1 2 3

76

Design...When designing automated systems for adhesive application, many factors must be considered.What is the end user hoping to achieve with automation? What are their constraints? What are the substrates or components to be bonded? What sizes are these components? Are there many variations in configuration or process? What are the environmental variables? What is the adhesive chemistry and any associated handling requirements? What are the curing rates, pot life and skin formation times of the adhesive or sealant? How many parts per minute, per hour, per shift need to be produced?

Once we have answers to these questions and many more, we will then analyse the facts and data. Our team will then work on a process which we call Concept Development. This will be presented to the customer or client and the concepts explored. Once agreement has been reached on the concept stage the detailed design work can begin using 3D CAD. We will further consult with our customers during the design process to ensure that all needs are met.Once sign off is achieved the process of build can begin.

Build...Every build has to start with a plan. The build plan sets out the timescale of every step in the build process and is monitored throughout to ensure critical targets are met with any issues highlighted with the customers in advance.

Many of our parts and compo-nents are held in stock, however there are always specialist com-ponents that have to be machined or fabricated to a specific design. Once assembly is under way, functionality testing is conduct-ed as each section or system is completed. Upon completion of build full testing is then carried out and calibration undertaken to agreed specifications with our customers.

The final phase of build is where the customer is invited to witness trials undertaken with their com-ponents on the new automated line.

Integrate...Often our equipment becomes integrated into the production lines of our customers. We will work with your engineers and other equipment suppliers to integrate our systems with theirs.

Usually discussed in the Design Stage, we will ensure that seamless integration is achieved. Where customers have a preference for a particular brand of PLC Control, or desires commonality of pneumatic components with existing plant specifications, we will work to ensure this is factored into the design.

Latest PLC / IT Architecture, Industry 4.0.

I4.0 envisages an environment where multiple machines, devices, sensors, and people connect and communicate with each other via the Internet of Things (IoT) or the Internet of People (IoP)[10]

Information transparency - the transparency offered by Industry 4.0 technology provides operators and management with large

amounts of information needed to make appropriate decisions. This interconnectivity facilitates operators in collecting data and information from all points in the manufacturing process, increasing functionality and identifying areas that can benefit from innovation and improvements to efficiency.

Technical assistance: The ability

of assistive systems to support human operators by aggregating, visualising and analysing information comprehensively for making informed decisions and solving urgent problems on short notice. Also, the ability of cyber physical systems to physically support humans by conducting a range of tasks that are unpleasant, too exhausting, or unsafe for their

human co-workers, the rapid rise in use of the Cobot is an example of this.

Decentralized decisions: The ability of cyber physical systems to make decisions on their own and to perform their tasks as autonomously as possible. Only in the case of exceptions, interferences, or conflicting goals,

are tasks delegated to a higher level

One example of the advances in technology available to our customers is the use of intelligent distance measuring and vision systems which will determine a component configuration and apply the adhesive where needed without operator intervention. This

means that full flow process can be adopted rather than inefficient methods of batch production with multiple operator setups for different components and product lines.

The pace of change and innovation seems to increase rapidly every year.

It is essential that the latest versions of PLC Controls, intelligent sensors and devices

“One of latest buzz words being - Industry 4.0, often now shortened to I4.0 or just I4. It is a word to describe what is being billed as the

Fourth Industrial Revolution.”

are evaluated to ensure our systems remain relevant. Whilst reliability is often established through experience, the pace of change is such that what was the ‘best on the market’ 2 years ago, may be far behind in terms of potential benefits to the customer

now.

We are constantly evaluating new systems, drives and sensors to ensure that we use components that will help you, the customer to stay at the front of your game. Keep up with change...

98

Smart Valves with Self-Diagnostic Monitoring

Grunfeld work closely with FESTO AG, a world leader in pneumatic components and automation control. FESTO AG were the first company worldwide to develop ‘digitised pneumatics’

For the first time ever, the functions of a valve can be controlled and changed by software without having to modify the hardware. This brand-new intelligent technology, which combines pneumatics, electronics and software control, can be used to realise simple directional control valve functions through to complex motion tasks which were previously restricted to servo-pneumatics or electric automation. Diagnostic functions for condition monitoring and reduced energy consumption can also be implemented more easily.

App-controlled valvesOne valve variant: a single valve replaces over 50 individual components!

This new valve technology can be used for a wide range of products, functions and com-plete solution packages. The only prerequisite is a valve design with multiple degrees of freedom for actuation, as well as integrated data acquisition and processing suitable for a cyber-physical system. The overall economic advantages for both the machine builder and the operator as a result of the valve’s variabili-ty are immense.

Proportional pressure regulationSave space and hardware costs by combining the functions of two individual and independent proportional pressure regulators in just one valve, including with vacuum!

Model-based proportional pressure regulationWith model-based control, there is no need for external sensors. By storing fewer boundary parameters for the system, such as tube length, tube diameter and cylinder size, the anticipatory control system ensures maximum accuracy, as the app can compensate for a drop in pressure and volume using the control technology.

Leakage diagnosticsFewer system downtimes and faster fault detection due to preventive maintenance. Separate diagnostic cycles and specific threshold values enable you to detect and localise individual leaks in the application operated by the Festo Motion Terminal.

ECO driveReduce costs by operating your actuator with the minimum pressure necessary for the load. This eliminates the rise in pressure in the drive chamber at the end of the movement. This allows energy savings of up to 70%. With a single DSBC32-100 with a 2 kg load, this amounts to a saving of approx. €100 a year.

Presetting of travel timeFor quick and easy commissioning and stable operation, all you have to do is enter the travel time for the advancing and retracting mo-tions. The travel time is taught in by adapting the exhaust air flow control function and is then maintained. The system automatically adjusts the values in the case of influences such as increased friction due to wear.

1110

...with high speed,

maximum throughput

systems.”

high speedmaximum throughput systems increasedaccuracy &efficiency

profitability

result in Relevant automation will without question, have a positive impact on your bottom line. Automation in itself, will not necessarily improve throughput, where automation removes a constraint then throughput will be increased.

Perhaps most importantly, automation allows for very high levels of consistency to be achieved, by having total control of all your variables and managing them, processes can be undertaken with perfect repeatability over many thousands of cycles.

Product consistency is one of the key factors that contribute to consumer satisfaction. How many times has your experience been marred by an inconsistent product?

“Variability or inconsistency is evil, get rid of the evil” Jack Welch, former CEO General Electric

“Increase efficiency, accuracy, profitability...

... and MOST importantly:

consistency...

1312

High resolution photoelectric sensors and devices are really the ‘eyes’ of our systems, determining when parts enter the gluing area and when they leave.

These are often high precision laser devices to ensure maximum accuracy and highest speeds of operation. We also use devices and sensors capable of accurately measuring the sizes of components to determine the

paths travelled by the gluing heads.

We work with many manufacturers of photo optical devices and we do have our preferred choices – borne out by our experience over many years, in many production environments.

If you have a preference for a certain type or brand of sensor then we will try to accommodate these in the

“How does it know where to place the adhesive?”High resolution photelectric sensors for precision adhesive placement.

building of our systems.

“Our main objective is to build automatic dispensing systems that apply the right amount adhesive or

sealant in exactly the right place, every

time and quickly.”

1514

Advanced Vision SystemsHave you thought about automating the visual inspection conducted on your production line? Machine vision systems have the ability to capture and evaluate targets in two dimensions, making them very useful for automating

inspections once done by the human eye.

Most industrial inspections fall into one or more of the

four major machine vision applications.

There are four major machine vision applications. Most

“Take the guesswork out of your production processes with advanced vision

systems.

Guaranteed to improve overall product quality

and consistency.”example

Foreign Object

Checking foreign objects, flaws and defects

Dimension measurement

Positioning

Counting the no. of cartridges in a box

Detecting pinholes and foreign objects on a sheet

Measuring the coplanarity of connector pins

Positioning of LCD glass substrates

Detecting pinholes andforeign objects on a shee exampleMeasuring the coplanarity

of connector pins examplePositioning of LCD glasssubstrates

machine vision applications in various industries can be categoriesed into the four groups illustrated.

Advanced vision systems can be incorporated into your automated dispense system and can identify and verify that adhesive has been applied in the right area, can measure and verify bead sizes, can verify the correct application of primers and activators where photo-fluorescent dyes are added for inspection regimes. Alignments can be verified where pick and place options are specified after gluing application. The possibilities are extensive, giving the manufacturing entity assurance that their processes are correct in critical applications.

One major benefit offered is that parts incorrectly manufactured are automatically identified and rejected, ensuring the consistency of your product.

1716

“Bonding consistency creates quality products”

Ensuring your operators are kept safe...

Machine safety

Machine safety is of all importance to the way our systems are designed and manufactured. We only use materials and components from certified suppliers to ensure that relevant safety requirements are met and even exceeded.All electrical and electronics systems are designed and manufactured according to the IEC 60204-1 Standard (BS EN 60204-1:2018).

CE Marking

All our systems are CE Marked as conforming to the Machinery Directive 2006/42/EC.

To comply with the requirements of The Supply of Machinery (Safety) Regulations 2008, a machine needs to pass these tests:

• The machine must comply with the EHSRs (Essential Health and Safety Requirements) of the Supply of Machinery Safety Regulations.

• The machine must have been assessed as complying with the EHSRs.

• There must be a Declaration of Conformity.• The supplier must assemble a Technical File.• The supplier must provide the information necessary to

operate the machinery safely, such as instructions.• The supplier must have followed one of the prescribed

conformity assessment procedures.• The machine must carry a CE mark.• The machine must ‘in fact’ be safe.

Increase the quality of your products...Mostly we all appreciate a quality product, think of that pair of shoes that fitted perfectly the first time you wore them… 5 years later they are still as good as new! People will pay more for a quality product.

Why spoil a brilliant design with poor manufacturing process control? Of course, the adhesive or sealant has to be the right product for your substrates and joint design, but all too often the issue is with the way the product has been applied, process steps missed out to ‘save’ time.

Automation takes the guess work out of your process.

1918

Single & 2 Component

Systems

Smart touch screen HMI, process visualisation.

Visual Management and Connectivity

“Understanding Visual Management is an

integral part of Lean Manufacturing”

The five main steps of Visual Management are as follows:

1. What is right?2. What is wrong?3. What is done?4. What is left to be done?5. The delays

Grunfeld Automated Systems use Large Display Smart HMI Touch Screens to facilitate Visual Management in your factory. We will work with your team to ensure that key and relevant information is displayed as you want to see it.

Integration of our systems with your other systems is possible with inputs and outputs being exchanged seamlessly.

Whether the adhesives that you use are single or 2-component we can help you to automate.

Not only do Grunfeld manufacture automated dispense systems but we manufacture our own range of drum transfer pumps and precision metering systems to feed these materials to your production line.

We can supply total package solutions including the transfer pumps and precision metering system to ensure that correct flow rates are maintained and in the case of a 2-component adhesive or sealant, that correct mix ratios are maintained at all times.

Precision dispense valves for extrusion and spray applications are designed into our systems, taking account of chemical compatibilities between all our components and your adhesive materials.

To deliver the adhesive or sealant to the point of application we use our own specially designed FluidMeister TM Teflon High Pressure hoses. These hoses have unique properties with ultra-low permeability for both water vapour and oxygen and can withstand working pressures of up to 520 Bar.

2120

Making use of KISS* Design Principles...

Cost Efficiency Analysis

*KISS (/kɪs/), a backronym for “keep it simple, stupid”, is a design principle noted by the U.S. Navy in 1960. The KISS principle states that most systems work best if they are kept simple rather than made

complicated; therefore simplicity should be a key goal in design, and that unnecessary complexity should be avoided.

...ensuring: reliability, ease of use and lowest cost of ownership.

We have a fully functional demo line available for evaluation trials.Modular in design, fully programmable with multiple digital IO for concept development and evaluation testing. Single and 2-component application options.

This enables us to work with our customers to accurately predict and calculate increases in efficiency and throughput, highlighting potential cost reductions in your processes.

Watch it in action...

2322

2524

Grunfeld Fluid Dynamics Ltd:

+44 1626 912260info@grunfeld-fluid.com

grunfeld-fluid.com

“We’re always ready to hear about your adhesive dispense requirements. Get in

touch...”