Automated bagging removes production bottleneck
A
Mitsubishi Electric Automation Systems product story
Edited by the Engineeringtalk editorial team
Jun 18, 2008
The Q series PAC is a flexible unit with dual central processors, which Pennine uses in a mutual redundancy configuration, and a bespoke array of modules for each of the functions under control.
Pennine Healthcare has used Mitsubishi equipment to automate the sterile bagging of its range of Yankauers - suction devices used by surgeons to remove excess fluid from areas of the body during surgical procedures.
Pennine, based in Derby, makes an extensive range of single-use medical devices, all manufacturing being undertaken in a medical quality clean room.
With over 60 million individual products made a year, automation is vital as it helps avoid contamination through human intervention, maintains quality and consistency and contains costs.
A yankauer is essentially a rigid extruded PVC tube, with one end attached to a suction line.
The free end is chamfered to avoid sharp edges, has a series of radial holes and is angled for ease of use.
Further back along its length, the bore diameter is enlarged (through an air injection during extrusion) and a larger hole is provided to allow suction control during use.
As well as surgeons, they are commonly used by dentists and vets.
Manufacture of these has essentially always been partially automated, but until recently bagging them into poly sealed packaging was a manual process.
"We were aware that this was a production bottleneck, that the operatives had to maintain very strict hygiene routines and that inner packing was disproportionally expensive compared to the rest of the processes", says Plant and Systems Engineer Darryl Orridge.
"So were keen to look at automation".
Many of Pennine's manufacturing processes are unusual, if not unique.
Add to this the discipline required for clean room operation and its engineering expertise has to be first class.
"For us, manufacturing technology is not a commodity that can simply be bought in as required".
"It's a core skill within the framework of the company and we have a highly skilled team dedicated to the development of our own high-performance and sophisticated custom-built manufacturing systems".
Pennine has long favoured Mitsubishi for control technology and systems and it was the launch of the new Q series programmable automation controller (PAC) that encouraged Orridge to consider options for yankauer packing.
"The process can be broken down into distinct stages".
"We have to load the yankauer into the packaging machine, make the bags from a roll of flat tube polythene; insert the product into the bag then seal and label it".
200W Mitsubishi J3 servo axes advance the bag and the system involves a sealer/perforator, labeller, interlock, data handling and several other functions.
In total there are 262 input/outputs, all handled by a Q01 PAC plus an E1032 HMI (human-machine interface) for local control and monitoring.
The Q series is a flexible unit with dual central processors, which Pennine uses in a mutual redundancy configuration, and a bespoke array of modules for each of the functions under control.
Because the machine is compact, loading requires the products to travel a route around several obstructions.
This is done with a Mitsubishi RV3SB six-axis robot, controlled via the Q series.
The main conveyor within the cell is controlled by small induction motors with Mitsubishi 0.18kW FR500 inverters for speed matching.
"This is the first time we've used the new J3", Orridge said.
"Previously it's been the J2".
"By comparison the J3 is smaller, faster, more powerful and easier to programme; it's no harder to set up than a conventional AC motor".
Orridge has also made considerable use of fieldbus communications.
CC-link is used for communications between the robot bagging machine and packaging machine, While ASiSafe is used for the safety interlock.
"Fieldbus has been a revelation for me".
"It's so easy compared to conventional wiring: just run the bus cable around the machine and link in the various devices locally".
"I reckon we saved several days of wiring up and troubleshooting in the build phase and in use repairs and alterations are the work of moments".
"We have decided that CC-Link is going to be the company standard from now on".
Not what you're looking for? Search the site.
Google Ads
Contact Mitsubishi Electric Automation Systems
Related Stories
- Schneider keeps Sellafield ponds chilled and clean
- Electric-vehicle chargers use Moeller RCDs
- Tube-style cable carriers protect Guedel's cables
- Siemens helps secure safety of Heathrow T5
- Reo AC power supply used in Downhole Compressor
Articles by product category
- Consultancy and Services (904)
- Machine Building (4,537)
-
Engineering Design Software (6,199)
- Engineering Design Software (12)
- 2D CAD software (201)
- 3D CAD software (1,158)
- FEA and structural analysis software (371)
- Fluid, thermal, noise, vibration software (334)
- Simulation, modelling, validation software (918)
- Rendering, visualisation, styling software (197)
- Materials design and moulding design software (152)
- Process, instrumentation, automation software (259)
- Electrical design software (165)
- Publishing and documentation software (229)
- Maths, charting, statistics, QA software (318)
- Data, document management software (312)
- CAM, CNC, production management software (571)
- File conversion software, data capture (352)
- PLM and collaboration software (650)
-
Drives, Motors and Controls (3,371)
- Drives, Motors and Controls (1)
- Precision Motors and Gears (413)
- Industrial Drives/Controls (1,278)
- Linear Drives and Motors (114)
- Industrial Motors (498)
- Stepper and Servo Drives, Motors, Controls (1,065)
- Small Mechanical Components, Joining, Tools (1,981)
-
Control and Instrumentation (5,039)
- Plantwide control (1,330)
- Plant- and Machine-Wide Communications (1,178)
- Smaller-Sized PLCs (387)
- CNC and Motion Controllers (184)
- Mid-range and Large PLCs (201)
- Power Supplies, Uninterruptible Power (562)
- HMIs/Operator Interfaces (294)
- Logic Controllers, Timers and Relays (96)
- Cabling, Conduit, Signal Conditioning (807)
-
Monitoring, Measurement and Quality (5,476)
- Monitoring, Measurement and Quality (1)
- Data acquisition Software and Communications (494)
- Data Acquisition Hardware and PC I/O Boards (472)
- Electrical and Electronic Testing, PAT Equipment (631)
- Form/co-ordinate, optical, vision instruments (711)
- Gauges, Indicators and Instruments (441)
- Data loggers (423)
- Materials testing equipment (418)
- Telecomms/network test equipment, software etc (154)
- Testing and Calibration Services and Information (505)
- Testing, analysing and monitoring equipment (1,226)
-
Electrical and Electronic Equipment Design (4,172)
- Batteries, chargers and circuit protection (558)
- Connectors, Terminals, Busbars, Slip Rings (682)
- Enclosures and Equipment Cooling Fans (709)
- Knobs, Handles and Enclosure Hardware (423)
- PCs and Embedded Systems (800)
- Electrical and Electronic Subassemblies (370)
- Electrical and Electronic Components (630)
-
Materials and Processing (2,971)
- Materials and Processing (5)
- Materials and components (2,221)
- Rapid Prototyping (458)
- Materials processing and testing (287)
-
Engineering Industry News, Resources (6,098)
- Engineering Industry News, Resources (4)
- Engineering Business News, Views (388)
- Engineering Exhibitions, Events (562)
- Engineering Conferences (425)
- Engineering Seminars (400)
- Engineering Industry Developments, Awards (633)
- Engineering Guides, Newsletters (350)
- Engineering Recruitment, Employment (219)
- Engineering Training Courses (434)
- Engineering Education, Resources, Standards (840)
- Engineering Industry Reports, Surveys (597)
- Electronic Resources for Engineers (278)
- Health and Safety Legislation (402)
- Health and Safety Strategy, Risk Assessment (113)
- Health and Safety Consultancy, Software (175)
- Health and Safety Events, Training, News (278)
-
Powertrain Design (3,620)
- Powertrain Design (2)
- Bearings (947)
- Chains and belts (326)
- Gears, brakes, couplings and engines (1,445)
- Hydraulic Components (471)
- Lubricants (428)
-
Capital Equipment (3,395)
- Capital Equipment (1)
- Manufacturing Machinery and Plant Equipment (468)
- Production line blowers and fans (62)
- Compressors and Air Treatment (512)
- Electronics Manufacturing, Tools, Instruments (192)
- Electrical hardware (131)
- Machinery and Production Equipment (1,096)
- Robotics, Handling and Storage (933)
-
Sensors (7,103)
- Sensors (8)
- Accelerometers and Vibration Sensors (429)
- Loadcells, Force Sensors, Torque Sensors (705)
- Pressure sensors (622)
- Flowmeters and Flow Sensors (619)
- Level Sensors and Leak Detectors (528)
- Linear Position Sensors (401)
- Rotary Position, Tilt and Angular Sensors (548)
- Proximity Sensors (704)
- Gas, Chemical, Radiation, Magnetic Sensors (285)
- Humidity and Environmental Sensors (153)
- Temperature sensors (612)
- Vision and Colour Sensors (1,386)
- Barcode Sensors (103)
- Valves, Pumps, Process Hardware (3,636)
