Industrial automation / robotics2021–2022
Electrical design, wiring, robot programming and integration of a new line for the automatic assembly of paper boxes with plastic lids.
The new line had to process three incoming parts automatically: a folded paper box and two plastic lids. Each operation needed to form part of one controlled production cycle.
The main technical challenges were inserting the lids with very little clearance, reliable vacuum handling and applying the hot-melt adhesive evenly.
The work covered the complete electrical design and wiring, main and secondary control cabinets, safety components and sensors.
It also included the pneumatic and vacuum equipment used to handle the box and lids.
A FANUC LR Mate 200iD picks the box, opens it on a vacuum worktable and inserts both lids in sequence.
An IDEC HG3G-V8XT22MF-W HMI provides system settings and status information.
An Xmelt XM-12 hot-melt system with an HM-500 head was integrated into the line. The work also included testing, adjustment and staged commissioning of the complete machine.
The FANUC controller provides the main control layer. It runs the primary robot program, supporting background logic and the HMI interfaces used for setup and system status.
Three input conveyors deliver the box and two lids. The robot opens the box, picks a lid, applies hot-melt adhesive and inserts it. The sequence is repeated for the second lid before the finished box is placed on the output conveyor.
A custom motor driver was developed for the 24V geared DC motors, using an ESP8266, an L298HN power stage with paralleled outputs, and separate custom logic and power PCBs.
It provides manual and automatic modes, movement in both directions during manual operation, a sensor input, automatic start and stop, separate acceleration and deceleration ramps, and independent speeds for each mode. Several units were built for the line and as a spare.
A functional production machine was assembled, integrated and tuned.
Industrial solutions
Robotic workcells and purpose-built equipment: integration, electrical work, programming, commissioning, service and troubleshooting.
Service detailsSpecialist service
Programming new applications and working on existing robotic cells, with particular experience in FANUC technology.
Service detailsHardware and firmware
Custom hardware, PCBs and firmware for MCUs, sensors, communications and device control, from initial measurements to a working prototype.
Service detailsA case study of a new production line for the automatic assembly of paper boxes with plastic lids.