Our client needed a solution for filling, weighing, assembling, welding, and labelling diagnostic kits for lab machines detecting medical deficiencies. The system was designed to handle two device variants with a changeover time of under 13 minutes. Plastic components were automatically fed, filled, weighed, capped, and laser welded. Completed assemblies were offloaded onto a puck system for labelling and inspection. Finally, parts are automatically loaded into trays that are automatically fed using a tray de-stacker.
The main challenge in this system was ensuring that the devices were accurately located and held for laser welding using location features on the two parts of the device. In addition, labelling issues had to be addressed to overcome the problems created by “high” devices. These challenges were compounded by the fact that the products were of two sizes.
Full circumference welding of two like materials.
100% weigh of product.
Cater for two different variants with automatic changeovers.
Accurate dispensing of multiple liquids
Designed for ease of cleaning and maintenance.
Cater for various device configurations and fill recipe
In-line labelling configurations
The Solution
The system was constructed around a linear mechanical indexing conveyor, tooled with two different sets of nests to suit two products.
Plastic reservoir bodies are bowl-fed and loaded onto the appropriate indexer nest. Bodies are then removed from the indexer and weighed. After reloading, the bodies are filled with preset volumes of liquids and then weighed again at the next station. Filled reservoirs are then again loaded onto the indexer nest. Good bodies then have caps fed, loaded and located onto them. The next process involves circumference laser welding and inspection of the cap to the bodies.
Reject parts are offloaded onto a stabilising conveyor for offline evaluation, while good parts are offloaded onto pucks feeding a labelling system. Due to the possibility of there being failed parts in the system (processing two parts on one nest), the label pucks carry single devices. The devices are then labelled and inspected.
Trays fed from a de-stacker are presented to an offload position, where the completed assemblies are inserted into the trays for final offloading.
