2K Polymer Systems is using a fully automated robotic production cell solution to check weigh and pack cartridges. Built by industrial automatiion specialist Aylesbury Automation, the robot based machine is helping the manufacturer to meet increased product demand and achieve a quicker response to customers’ requirements. The machine check weighs a range of cartridges and palletises them ready for transfer to the next process. One complete part is checked every three seconds.

2K Polymer Systems, is a leading supplier of grouts, mortars, fillers and adhesives for the private label products market, providing a full range of anchoring, sealing, bonding, filling and repair solutions. Its speciality is in chemical mortars and resin-based compounds for everything from performance critical professional markets to DIY repair applications. 2K’s combination of polymer formulation experience along with innovative packaging solutions demands high quality manufacturing processes and controls.

The solution provided by Aylesbury Automation has help to improve quality management and minimise manual handling. After filling, the cartridges are moved from the outlet of the cartridge filling and assembly machine by a DENSO VS-6577, 6 axis robot. The robot is equipped with a range of grippers to ensure all different styles of cartridges can be picked. The robot places each cartridge into a purpose-built weigh station. The check weight of each style of cartridge is selected from the DENSO Robot Teach Pendant, which is also the system’s HMI.

Cartridges which pass the check weigh station’s tolerance limits are placed systematically into a grey storage container. Rejected cartridges are placed in an adjacent reject bin.To minimise floor space, product storage containers are fed using a powered “L” shaped conveyor.

When each container is filled it is automatically discharged from the loading position and the next empty container transferred ready for processing. To maximise process eficiency filled cartridges are transferred to a holding station during storage container changeover.

There is no PLC in the production cell, all the machine’s functions are coordinated by the multi-tasking robot controller using Devicenet I/O, and this delivers a considerable cost saving. Six background tasks operate to control 256 I/O points and all status and error messages are shown on the robot HMI.

2K Polymer Systems been using DENSO robots for some time in the manufacture of products. Encouraged by the low capital cost of the Aylesbury Automation solution, the company is now exploring other processes which might benefit from robotic assistance.

Aylesbury Automation, a system integrator for AA Robotics DENSO robots, is the UK`s leading supplier of productivity solutions to the manufacturing sector with over 48 years experience gained throughout almost every type of industry. The company’s core products include a full range of tooled vibration parts feeders, associated handling equipment, robots and rivet setting machines, enabling a complete and often turnkey service to customers. The business runs a full IT capability, using networked computers and sophisticated SolidWorks 3D CAD system and is ISO 9001:2008 and Investors in People accredited. Aylesbury Automation employs approximately 25 people at its UK headquarters and manufacturing plant located in Aylesbury, Buckinghamshire.

Have you a requirement?

Should you have any potential problems or projects you wish to discuss, then one of our sales application engineers will be willing to visit you on site to give assistance. Alternatively, you are most welcome to visit our company at Aylesbury to view our premises and to discuss your particular application.

Aylesbury Automation is accredited to ISO 9001:2008 and Investors in People.

For further information, advice and customer services, contact:
The Sales Department
Aylesbury Automation Limited
Unit 2 Farmbrough Close
Stocklake Park
Aylesbury
Buckinghamshire
HP20 1DQ

Telephone: +44 (0) 1296 314300
Fax: +44 (0) 1296 482424
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