FAQ’s

Q - With pneumatic assembly machines, if a reject is detected, a “shift register” in the control shuts down each station as the rejected part is indexed through the remaining stations. The part is then removed at the reject station. How do you stop the manipulators on a cam-operated machine?

A - On cam-operated machines, manipulators and auxiliary stations will continue to cycle. The “shift register” is used to keep the piece part grippers open, so no further parts will be added to the reject assembly. In critical situations, we recommend the tooling be mounted on a pneumatic slide. In normal operations, the slide is always extended. This will also provide for overload conditions and the shift register may retract the slide out of the work zone when a rejected part is detected.

Q - How many stations will I need to fabricate an assembly consisting of nine
parts?

A - You should typically plan on having three working stations more than the number of parts to be assembled – load, unload, plus an extra one. A VELOMAT with a 24-stop Rigidial indexer and 12 manipulators or auxiliary stations, plus intermediate checking stations would be ideal to fabricate a nine-part assembly.

After placing a part or performing an operation, the next station should be a probe station to verify that the operation was completed correctly. The easiest way to do this is to utilize the inspection probe mount, which is a standard option on the pick-and-place “motion modules.”

Q - We presently use pneumatically operated assembly machine components around a cam indexer with a dial plate. We can build a 12-station basic machine without components, tooling or controls for around $43,000 (Base $3,000, Indexer with dial plate $4,000, 12 stations @ $3,000 or $36,000). Why should we spend more for a cam-operated machine?

A - The typical cycle time of most pneumatic machines is about 3 seconds or 1,200 parts per hour. The VELOMAT, because of its mechanically synchronized motions, is capable of running substantially faster, at about a half-second cycle time or 7,200 parts per hour.

Even if extra speed is not required, the VELOMAT 1000 will most likely be more economical when considering the following:

You Save on Design Time

When using VELOMAT, the only design time required is for the grippers, pick-up points on the end of bowl feeder tracks and the tooling nest (which attaches by “T” Slots on the dial). It is not uncommon to complete the tooling design and detailing for the VELOMAT in about 60 hours. To save you even more time, a complete set of CAD files is provided for each machine ordered.

You Save on Controls

Each cylinder on a pneumatic machine must have a solenoid valve and, typically, a proximity switch reading each end of its stroke, plus a lengthy program must be written to cycle them. Each station of a pneumatic machine will usually have two air cylinders. A twelve-station machine would require 24 double solenoid valves or 48 solenoids and 48 proximity switches to monitor the position of the cylinders. This necessitates many hours of wiring and plumbing. The VELOMAT is mechanically synchronized and driven by a single motor. To operate it, you just turn the motor on. Controls are only needed to operate the grippers and perform a “shift register” function.
 

You Save on Assembly Time

The VELOMAT is delivered completely assembled, and tooling-up can begin immediately. Assembly and set-up can usually be completed in 5-10 days.
 

You Save on Debugging Time

This is something that always seems to take forever. However, with the VELOMAT, debugging time is drastically reduced. Each machine is equipped with a hand crank that is used to cycle the machine during setup. A typical pick-and-place station will have a bowl feeder with a track to present parts to the gripper. Using the hand crank, one can rotate the machine until the grippers are at the beginning of the cycle and positioned to grip the part in the bowl feeder track. The output of the programmable limit switch operating this gripper is programmed to close the gripper at this point. Now crank the machine to a point where the gripper is about to place the part in the tooling nest on the dial. Another output of the limit switch is programmed to open the gripper. As you continue to crank, the machine table will index and the gripper will return to the bowl feeder track. The programmed cycle can now be carefully observed and any corrections can be made to alignment or timing. After the first station is operating satisfactorily, the remaining stations are done in a similar manner. The programmable limit switch has a speed compensation feature, which is extremely beneficial and is used to accomodate any delays created from items such as switches or solenoid signals. So, whether you are running at 10 parts per minute or 120 parts per minute, the grippers will always operate at the same point in the cycle. The built-in programmable limit switch constantly monitors at what point of the cycle the machine is in.

Velomat’s innovative design incorporates several patented features that deliver a unique combination of smooth, gentle motions and accurate, high-speed positioning at impressive cycle rates for a very affordable price.

Velomat base machines are delivered fully assembled, so tooling-up the machine can begin immediately. Only the feeding devices, tooling nests, part grippers and control components need to be added. This makes Velomat ideal for both end users with some in-house engineering capabilities and for those working with a local design house. It is not uncommon for tooling to be designed and detailed in a fraction of the time typically required for a specially designed assembly machine.

The reliability of the Velomat family of components has been well proven in a wide variety of applications throughout Europe, including pharmaceutical disposables, plastic molding and electrical/mechanical sub-assemblies. The Velomat, as well as a full complement of engineering assistance and technical support, is now available to you in North America through Indexing Technologies Inc.


 

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37 Orchard Street
Ramsey,  N.J. 07446

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