We recently had the opportunity to develop a machine for Quooker. The aim of the machine is to partially reduce the diameter of one end of the tube, which measures approximately 5 cm in length. This process was previously carried out semi-automatic, which was labour-intensive and – due to the presence of chemicals – uncomfortable. Furthermore, process control was limited.
Smart Automation worked with Quooker to develop an automatic pipe end forming machine, resulting in:
- Greater process and quality control
- Longer tool life through predictive maintenance
- No uncomfortable situations due to chemicals
- Reduced lubricant consumption
- significantly less rejected products
- Approximately 3 employees freed up for other work
Process
The developed machine goes through the following steps:
All process measurements are processed in the Beckhoff PLC and displayed on a clear HMI. The process measurements led to surprising insights: early stages of mettalic deposit on the press tools is detected in time, allowing for proactive maintenance. This not only prevents rejected products but also results in significant savings on tooling costs.
The machine
The machine’s design has turned out to be nicely compact. This is partly due to the orientation of the press mill: it is vertical. Furthermore, in the overall design, we have taken into account the possibility of connecting subsequent machines to this machine in the future.
Result
Both our client and ourselves are satisfied with the end result. Employees no longer need to come into contact with the chemicals; there is greater process control, fewer rejects, reduced lubricant usage and ample capacity. The production machine is able to achieve the desired weekly production output almost autonomously within three days.
An excellent collaboration in which Smart Automation provided a clever machine concept, smart software and a reliable machine.
Technologies used: Dosing technology, hydraulics, Beckhoff, measurement technology, process control
