Description

• This machine was designed to produce pin back buttons.

• It is capable of producing two different shaped buttons in various quantities, and is able to package the buttons or simply dispense them.

• The main material handling device is a Gantry style robot.

• Within the station there is a rotary table, 2 pneumatic presses, 6 custom designed forming dies to crimp buttons, paper cutting dies, a conveyor system to feed boxes, a hobby robot material handler, and a touch screen at the HMI.

        Operation

• The user enters various setting from the HMI touch screen.

• The user selects from pre-defined pictures or decides to have their picture taken.

• The user can also decide to select a round or square shaped button, as well as the quantity to be produced.

• The final input from the user is packaging method, they can choose to drop the button(s) out a chute or put them in a box.

• The image is then sent off to the printer which prints directly into the cutting station.

• An overhead gantry robot is used to move the various parts into forming dies on the assembly station.

• In the assembly station there is a vision camera to inspect the picture's orientation and correct it if necessary.

• In the dispensing station the pin backing is inspected using light sensors to ensure it is in the correct orientation.

• The assembly station has pneumatic presses which combine all various components to produce a finished button.

• Once the button is complete assembly will present it to packaging.

• The packaging station equipped with a small hobby robot will pick up the finished button and place it according to the users input.

        Error checking

• At assembly a DVT 630(Design Verification Test )vision system checks for angular misalignment.

• This alignment is corrected using a stepper motor to rotate the lower die which holds the picture.

• In the dispensing station the pin backing is aligned using a DC motor and two light sensors.

• When light is visible through the two holes in the pin backing is properly aligned and the DC motor will stop rotating.

        Machine size

• The machine was designed for tradeshows and exhibitions, as such needed to be portable.

• The original design was shrunk to have a footprint of 4.5 x 4.5 square feet.