Page 11 - Industrial Technology magazine February 2021 issue

MACHINE BUILDING

At the cutting edge

AUTOMATION

AUTOMATION TECHNOLOGY FROM FESTO SITS AT THE HEART OF
A NEW ROTARY ASSEMBLY CELL DESIGNED AND SUPPLIED BY
PCE AUTOMATION. THE NEW PRODUCTION CELL ALSO CONTAINS
FESTO MINI SLIDES, AXES, CYLINDERS, VALVES AND GRIPPERS,
ALL OF WHICH CONTRIBUTE TO THE HIGH PRECISION
ALIGNMENT REQUIRED FOR STANLEY KNIFE ASSEMBLY

tanley Tools have been synonymous with quality, we had every confidence that their product
reliability, innovation and value for more than 175 portfolio would offer the quality and precision
Syears. To maintain their competitive edge, owner that the Stanley knife assembly application
Stanley Black & Decker is continuously investing in demanded. Breadth of product choice, coupled
automated production techniques where these can add with Festo’s on time delivery record and parts
value for the brand. One area that was identified for availability, were critical in helping us win the
improvement was the blade assembly line for plastic-
handled knives. The process involves the assembly of four
components: the handle, blade, sliding mechanism and
blade fixing component. Because it requires a high level of
precision and repeatability, this task has traditionally been
done by hand. Premier Bowl Feeders. Introducing the knife blades into
The customer required an assembly cell that could be the assembly cell raised a particular challenge for PCE.
used to produce safety knives with two different sizes of The 9mm and 18mm length blades are presented to the
blade capable of swapping production efficiently between assembly cell in stacks of 400, but each blade is only
their 9mm and 18mm width options. To meet demand, a 0.4mm or 0.5mm thick, which makes them tricky to pick
cycle time of 20 parts per minute was necessary. In and place accurately.
addition, Stanley Black & Decker needed a compact There was a real risk of the blades jamming and
solution to fit in the existing footprint at their UK halting production if not correctly positioned, so it was
production facility. critical to be able to pick off one blade at a time and place
PCE Automation won the contract to design and build it in the correct orientation. PCE used magnets to hold the
the new automated assembly cell under competitive Stanley Black & Decker contract. As a systems builder, we blades effectively. Festo grippers are used to pick and
tender, against international competition. Ultimately, appreciate the proactive support that Festo offers in place all the other components.
Stanley Black & Decker decided to opt for a UK supplier exploring alternative solutions. We also found their online The nerve centre of the new rotary assembly cell is the
who could offer good levels of service support. PCE software tools particularly helpful, especially the ability to Festo CPX-AP-I (see box-out), which acts as a single
Automation, in partnership with Festo, was able to track parts and lead-in times online.” control network and facilitates the use of a single cable for
demonstrate the levels of responsiveness and aftersales To facilitate fully automated assembly of Stanley all communications and power. It also allows flexible
support that their customer was looking for. knives in the space available, PCE Automation designed positioning of valve terminals and other components
Ellen Blackie, senior project manager, PCE an eight-station rotary assembly cell. The blade handles around the assembly cell – all of which simplifies
Automation, comments: “As an existing Festo integrator, are held in position on the central rotary assembly and the installation and lowers overall cost. Festo DGST precision
components, including blades, are mini slides and grippers are used for accuracy and
placed with high precision to build up repeatability in presenting the plastic components for
the final product. The fully assembled assembly. These are complemented by DFM guided
Stanley knives are subject to camera actuators and air preparation units from Festo’s core Blue
inspection for quality control as they Star range of best priced and availability, pneumatics.
leave the cell on a conveyor. Josh Roberts, Festo business development consultant,
The customer did not want the says: “The Stanley knife rotary assembly cell presents a
assembly cell to require constant great example of how automation can be applied to
overseeing by an operator. So, hoppers replace manual repetitive tasks and deliver benefits, such
are used to feed components down to as improved productivity and quality.
vibrating bowl feeders. The hopper feeds “PCE involved Festo at the earliest possible stage,
will keep the cell running for which meant we could work in partnership and combine
approximately one hour without the our respective specialist knowledge as system builders
need for operator intervention. The and automation specialists to deliver the optimum
bespoke vibrating bowl feeders were solution for Stanley Black & Decker.”
manufactured by PCE’s sister company MORE INFORMATION: www.festo.co.uk

January/February 2021 • INDUSTRIAL TECHNOLOGY 11