8 INSIGHTS 2018
A strategic collaboration between SMC Pneumatics and AEM Unicore has
been a catalyst in the success of manufacturing AEM Unicore’s Automatic
DUO Core Machine model UCM440A.
SMC and AEM, a South Australian-based company that designs
and manufactures special-purpose equipment for the transformer
industry, have partnered in the manufacture of AEM’s Automatic
DUO Core Machine. The machine streamlines the manufacturing of
transformer cores through its key features. Fully programmable for
flexible production, the machine produces fully formed half cores and
eliminates the need for manual forming. It features a robotic arm and
gripper, and an automatically adjustable core stacking and transfer
system. It is fully automated and therefore improves productivity, quality
and safety. With the ability to run just-in-time (JIT) production, users
can enjoy the convenience of compact and lighter cores that do not
compromise on quality.
AEM customers also have the additional choice of selecting a double
decoiler with remote operation as an option.
The prospect of a partnership was realised when AEM noticed
the substantial help and support that SMC was offering right from the
inception of the project to manufacture the DUO Automatic Core Machine.
Peter Tedore, engineering design and project manager at AEM, said:
“The service and support that we received from SMC exceeded our
expectations; they were of more help to us than suppliers had been in
the past.”
The complexity of the project brought about
challenges in ensuring the compatibility between
components of the machine. SMC’s wide product
knowledge and offerings were key in enabling
AEM to simplify and accelerate this design and
selection process.
“One of the most critical components used
in this machine is the pivoting linear drive
arm,” explained Tedore. “We felt that SMC had
a superior product compared to other products
in the market. We were impressed with the ease
at which SMC products integrated with other
control components used. We used EtherCAT for
communication and, after we plugged in and set up
each component, the system worked seamlessly.”
Jason Sutton, an area sales manager for SMC
Pneumatics Australia and New Zealand looking
after AEM, said: “SMC wants to work with our
customers to know what they need to solve the
challenges they face and is always looking at how
SMC can improve existing products to help them
solve those challenges.”
According to Sutton, the hidden vacuum
ejectors used in this project are an example of
how SMC offers products that have superior
performance compared to existing products. The ejectors are about
half the weight of their predecessors, produce twice the vacuum flow
and have half the wiring to control.
Another device that stood out for Sutton is the electric drive and linear
card motor. The visible vacuum heads that pick and place the laminate
sheets are mounted a reasonable distance away from the carriage, which
induces a large moment onto the drive. The drive was selected as being
able to continuously handle the load at the same time the speed was
requested. SMC was able to provide its LEJB63 belt drive with a kit to
mount AEM’s selected Beckhoff motor directly. This drive arrangement
negated the need for a gearbox to be used.
During the design stage, AEM was unable to accurately measure
laminate thickness, as many standard measuring instruments required
being physically moved in and out of the measuring area. For the required
accuracy of 1 μm, the favoured solution was to be a laser measuring tool.
In response, SMC suggested using its linear motor as it could provide
1.25 μm accuracy, 20 mm of displacement and some clamping force at the
point of measurement to increase the repeatability. Compact controllers
with easy-to-use interfaces made for effortless integration.
AEM has delivered and commissioned three Automatic DUO Core
Machines in a transformer core production facility in the USA and three
more machines are currently in production.
SMC Australia | New Zealand
http://www.smcworld.comcase study
Automation revolutionises transformer
core manufacturing