Challenge:
Fully automate the laser engraving and marking of stainless-steel labels and tags. Remote operation and monitoring required, along with simple manual operation when needed
AI Website MakerFully automate the laser engraving and marking of stainless-steel labels and tags. Remote operation and monitoring required, along with simple manual operation when needed
Work with customer to find the ideal solution. Multiple laser manufacturers and integrators approached to ensure marking specification, process throughput, footprint and functionality is achieved
100w SPI Redpower MOPA laser selected after research and testing with the help of Strathclyde University's Metallurgy Department. SPI's 100w MOPA laser's beam control allowed for precise engraving and marking, achieving the final customer's exacting specifications
Due to the high purchase cost of multi-axis robots, a used OTC Diahen unit was employed. This FD-series robot was adapted from it's original welding application, to it's new role of manual handling label trays
With a suitable robot selected, the task of integrating the robotic process began - A large label capacity, with a small physical footprint was required. The final circular design allowed for a near 360° racking system capable of storing 342 carrier trays, with each tray able to accommodate between 50 to 200 labels, depending on size
To unlock the full capabilities of the laser, a CNC X-Y-Z table and galvo mount was integrated. The EZCad engraving software was capable of seamlessly running this, together with the laser beam galvo head. This added flexibility not only reduced process time, but also improved engraving and marking quality
User safety is paramount when working with high-powered lasers. Therefore the laser process was fully shielded and interlocked inside a sealed enclosure with a sliding OD7+ viewing window to facilitate manual loading when required. Interlocked fume extraction and automatic fire detection/suppression systems further enhanced safety
Specify and procure a CNC profile cutter for the production of stainless-steel tag and label blanks
Water-cut, press-cut, plamsa-cut and laser cutting tools were compared and assessed for performance, cost, flexibility and production quality
Operation cost, cut quality and flexibility made laser cutting the go-to choice for the customers needs. A new fibre-laser machine would have reduced operational costs, but ultimately a used 1500w CO2 profile cutter was chosen for it's significantly lower up-front purchase cost
Once sourced, the 1.5M X 3M cutter bed, control cabinet, water chiller and extraction system had to be transported from Rainham, Essex to Clydebank, Glasgow. The 5000kg of combined equipment then had to be installed in the customer's facility
Once sited, levelled and bolted down, the electrical installation was completed. A 'screw' air compressor and dryer was spec'd and installed, along with the extraction/filtration system, chilled water system and compressed gas services
The machine's considerable age and time in storage necessitated extensive recommissioning. Water damaged PCB's, control gear and components were repaired or replaced as needed, the HV and vacuum systems were upgraded and the beam optics, cooling and CNC systems cleaned and serviced
Design and manufacture a chassis dynamometer (rolling-road) capable of being towed by a small van or 4X4 for remote vehicle power and diagnostic testing
A high accuracy, eddy-current braked, Dastek dynamometer was chosen as the foundation of the mobile unit. A suitable trailer - Ifor Williams 3500kg 1.5M X 2M twin-axle was sourced to permanently mount the dyno' into. An all-up weight of 1966kg meant that most medium vans would be capable of towing the unit
To facilitate vehicle access onto the rollers, 6mm thick aluminium treadplate ramps, designed in 4-sections were manufactured. The lightweight, sectioned design allows for transportation in a small-to medium sized van
To protect the rollers, eddy-current brake, load-cell and power electronics from the elements, a lightweight but robust 3mm thick aluminium cover over the roller section and a 6mm aluminium cover over the brake section was designed and manufactured. The brake cover incorporates a quick-release section for airflow when in use
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