Consumer Goods Industry

Every company that produces a product does so using a unique manufacturing process that is designed to fit their business model and manufacturing needs. There comes a time when the manufacturing process will need to meet higher productivity, reliability, quality, availability, increased performance, and reduced operating costs and defects. Our experienced engineers have the expertise to work with you to design, build, and implement a customized, automated solution that fits your specific production process and budget.

Dial Table Assembly & Test Cell

Key Functions

Gripper inspects proper part orientation/flips if correction needed
Silicone spray station onto part
Ultrasonic Welding
Inkjet date code printing to part
Vacuum Pick and place
Part Testing
5 different part types

Components

6 Station Index Ring Dial Table
Manually loaded/unloaded part conveyor belt
Automated Assembly of 2 Different Part Types
Laser Inspection Sensor
Vision/Inspection cameras for potential defects
Two Position walking beam with gripper orientation function
6 Hard Chrome Plated Part Nests with empty nest detection
Poka-yoke sensors
Silicone Spray Application
X,Y,Z Linear Actuation Placement
Pneumatic Vacuum Pick and Place
Inkjet Date Code
Pad Print
Reject Chute
Horizontal & Vertical Press Cylinders
Ultrasonic Welding
Data Storage
3D Printed Part Sleeves

The Project

Alliance won the AAV Assembly machine project because we could resolve the four manufacturing challenges; condense floor space, reduce labor, increase rate speed, and finally remove the bottle neck at the leak test station. The original process used 4 operators in 2 separate stations to produce two separate sized products at a rate of 350 parts per hour. Alliance was able to provide a single assembly cell that would accommodate both sized parts using different nests. One operator was able to operate the machine and pack-out the products all while producing 720 parts per hour. This increased rate was achieved by putting all key functions in one machine and having the parts on a dial table.

Wire Whip Hub Machine

Key Functions

Parts feed to a bowl feeder using a pre-feeder holding 30 minutes of parts
Automatic loading onto indexing dial table
Spot facing operation
Pneumatically controlled drilling units
Detection system to verify tools are not broken
Coolant system to provide a constant wash of the machining process to remove chips
Vision system to confirm key orientation

Components

Pre-Feed System
Hub Bowl Feeder
Sound Proof Deadening Enclosure
Pick and Place System
3 Position Indexer Dial Table
Tooling Nests
Vision System
Precision Link Conveyor System
Chip debris trough
12 Small Pneumatic Drill Units
4 Large Pneumatic Drill Units
Tote Pack Out System
Central Vacuum System
Coolant Wash System

Wire Whip Hub Machine​

The Project

Alliance won the AAV Assembly machine project because we could resolve the four manufacturing challenges; condense floor space, reduce labor, increase rate speed, and finally remove the bottle neck at the leak test station. The original process used 4 operators in 2 separate stations to produce two separate sized products at a rate of 350 parts per hour. Alliance was able to provide a single assembly cell that would accommodate both sized parts using different nests. One operator was able to operate the machine and pack-out the products all while producing 720 parts per hour. This increased rate was achieved by putting all key functions in one machine and having the parts on a dial table.

Consumer Goods - Wire Whip Hub

Extruded Deck Board Stacking System

Key Functions

Multiple unload/load bays  2-axis gantry
End of arm tool consists of (4) 48-inch-long x 3.5-inch-wide vacuum gripper pads Capable of picking and placing a single layer of 8 boards in 2.5 minutes
Stack height of 12 layers with the following board specifications:
Length: 12’ to 20’
Width: 5.5”
Thickness: 1”
Weight: 2.3lbs/ft
Temperature: 135℉ – 150℉

Components

2-Axis Gantry System
24’ x 16’ Gantry Frame
End of Arm Tool with (4) 48”L x 3.5”W Joulin Vacuum Gripper Pads
5.3’ Y Axis Movement, 20” Z Axis Pneumatic Actuation
Regenerative Blower
Cart Dock Station with (2) Docking Pins
(2) Cart Present Sensor
(1) Allen Bradley Control System

The Project

Manually stacking extruded deck boards is a repetitive job that requires strenuous labor and operator’s full attention. This stacking system is designed to allow for multiple unload/load bays and uses a 2-axis gantry. By implementing two of these gantry systems, our customer was able to free up multiple material handlers which allowed them to add value to other areas of the business.

Automated Panel Saw

Key Functions

11,000+ variations available
20 seconds or less
Target speed of 40 fpm
System adaptable for larger arbor sizes
Cuts a maximum of 15” from leading edge
Minimum cut of .5” to 1” from leading edge
Makes two cuts along and wide section
Transfer conveyor
Saw assembly
Product stop & hold assembly
Vacuum system
Controls integration with MES system

Components

(2) Chain Driven Live Rollers, 31.5’ L x 36” W x 33” H, 2.5” diameter rollers, 9” roller centers
Saw Motor, 7.5HP, 460VAC, 3 phase, Nameplate RPM 3,490
20” (500mm) Diameter Blade with .70 (18mm) Arbor
7.5HP Variable Frequency Drive with Brake for Saw Motor
Saw Stop Motion Monitor
(3) Allen Bradley Kinetix Servo Motor and Drive
(3) Gearbox with Pinion
(13) Bearing Block
Saw Enclosure
Extruded Aluminum Frame with Clear Lexan Panels
Access Door
Solenoid Locked Safety Access Switch
220 CFM, 5.5HP Vacuum Unit, 2” Inlet, Continuous Rated Duty Cycle
55 Gallon Drum with Separator
Funnel Tooling Under Saw Enclosure
2” x 10’ Flexible Hose
(2) Safety Light Curtains
(2) Safety Interlocked Access Doors
Allen Bradley Programmable Logic Controller
Keyence Wireless Handheld Scanner
Label Printer, 2D (QR Code)
Card Swipe Interface
Opto Touch Start Button

The Project

This system was installed to ensure accuracy in cuts and to make the operation safer for employees. By having the operator load the panels and scan each product label the system takes over the dangers part of the process and automatically adjusts the saws for a perfect cut every time. The operator does not have to do anything further until the system sends the completed product to the unload area where it is physically removed from the line.

Manufacturing Automation Opportunity Areas:

  • Assembly
  • Inspect
  • Palletizing
  • Packaging/Shipping
  • Testing
  • Material Handling

Companies need a partner they can trust to install robotics, vision, laser inspection, sensors, and part testing into their production lines. Whether it is a fully automated line or specific tasks, automated equipment is ideal for completing repetitive tasks like moving parts across stations, applying sealants, and joining materials.

Is Manufacturing Automation Right for your Business?

  • Is your current manufacturing process struggling to meet quality standards?
  • Do you have a new product or change to a product that needs added to your production process?
  • Is it time for your company to bid for new business opportunities and gain assistance?
  • Have you struggled with labor requirements for production?
  • Are your current customers requesting new functions or testing to be integrated into production?

Why you should Join the Alliance

When you partner with Alliance Automation you're getting more than just a robotic solution.

Alliance Automation is here to design, build and install a custom solution to fit your exact needs. Our products will solve your business challenges. How? We follow the Alliance Proven Process. Alliance Automation doesn’t just sell you a product; we get to know your business and find solutions to help you reach your goals.

 What we offer:

  • Project Review
  • Risk Analysis and Risk Assessments
  • Budgetary and complete project proposals
  • CAD Designers
  • Fabrication
  • Toolmakers
  • Machinists
  • Mechanical Engineers
  • Electrical Engineers
  • Controls Engineers
  • Project Managers
  • Full Implementation teams