Filter Pleat Bonding System
Project Description: This system is a custom non-robotic machine designed to bond pleated filter bodies in an “edge-to-edge” configuration.
Operation: The system starts with a pre-processed pleated filter media “pack”. This pack is given an initial forming operation and restrained in position. A fully automated precision bonding system then applies adhesive to one edge of the pleated pack. After the adhesive is applied, the pack is shuttled into a forming/shaping mechanism the re-forms the pack into an obolid shape with the two pack edges parallel to one another. The pack is then “closed” whereby the two edges are brought together simultaneously to prevent movement and smearing of the adhesive. This tightly constrained pack is then ejected into a stainless steel sheet metal form to retain its physical alignment during subsequent conveyor oven epoxy cure cycle.
Mechanical Architecture: The system is on a custom heavy duty 80/20 frame, with control enclosure underneath, and all operational hardware on the top deck for easy maintenance.
Motion: Part Load/Unload: Fully pneumatic under PLC control. Sensors: Proximity, Inductive, through-beam and magnetic.
Vision: N/A
Safety: System is fitted with a perimeter safety frame and standard light curtains.
Primary Challenges and Solutions:
1. Adhesive application and integrity, part geometry: The adhesive application and integrity is critical to the functionality of the end item.
Solution: A custom servo system was developed using a high pressure Graco adhesive dispensing system to provide the necessary precision and reliability. Additionally, filter pack restraints and location features were developed and integrated into the machine to assure long-term reliability.
2. Product Variability: The product varied a great deal in certain geometrical features which could prevent automated processing.
Solution: A detailed tolerance analysis was completed to ensure the machine could accommodate all anticipated geometries of upstream processes.