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Automating an Old Drill & Rivet Machine: Revolutionizing Panel Assembly

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Automating an Old Drill & Rivet Machine: Revolutionizing Panel Assembly

Introduction

In the realm of manufacturing, the evolution of technology has paved the way for remarkable advancements. One such transformative project involved automating an old Gemcor machine that originally operated manually. The goal was to shift from a traditional one-button-push-per-rivet approach to a more efficient one-button-push-per-panel operation. Let’s delve into the details of this innovative project and explore how it has revolutionized the assembly process.

The Traditional Manual Operation

Before the automation project, the manual operation of the Gemcor machine involved a meticulous process. A technician would use a template, coated with blue ink, and lay it over a panel held together by manually drilled and installed rivets. The template’s ink is transferred through holes to the panel, creating a guide. The operator, guided by laser dots, would manually drill holes and insert rivets, repeating the process for each ink dot on the panel.

Transition to Automated Precision

With the automated system in place, the labor-intensive aspects of thte process have been eradicated. No templates or ink-dotting are required, and the operator no longer needs to constantly monitor the machine. The pre-assembled panel is effortlessly slid into the positioner, and after selecting the panel type and pressing the start button, the machine takes care of the rest. The clamps self-adjust to accommodate different panel thicknesses, enhancing flexibility.

Cost-Effective Upgrade

Remarkably, this automation was achieved at approximately 10% of the cost of purchasing a new machine with similar functionality. Though decades old, demonstrated reliable performance. Upgrading its capabilities while retaining the core manual machine proved to be a cost-effective alternative to staying competitive in modern times.

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Seamless Integration with Delta Sigma Controls

Delta Sigma played a crucial role in integrating the controls of the new positioner with the Gemcor machine, ensuring seamless operation. Despite the absence of CAD data for the aged panel design, the control system was ingeniously designed to operate from an Excel spreadsheet. Laser tracking technology measures hole positions for each panel type, simplifying user implementation without the need for CAD or CNC expertise.

The Self-Registering System

One of the notable features of the automated system is its self-registering capability. The operator doesn’t need to inform the machine about the panel’s position on the table. By aligning the panel against the X and Y reference edges, a single button sets all the clamps, making the system ready for operation. The X-Y table, controlled by servo motors, ensures accuracy and repeatability beyond human capabilities.

Bridging the Gap: Old Machines, Modern Automation

The project serves as a testament to the ease with which old machines can be upgraded using modern automation. While machines from the 70s, 60s, and even 50s may still perform admirably, staying competitive in the current landscape demands modernization. Integrating automation around a reliable manual machine can offer a cost-effective solution to enhance capabilities.

Conclusion

In conclusion, the transformation from a manual Gemcor machine to an automated, precision-driven system has significantly streamlined the panel assembly process. The project’s success showcases the potential of upgrading aging machines with modern automation, emphasizing efficiency and cost-effectiveness.

Frequently Asked Questions (FAQs)

  1. Q: How long does it take to assemble a panel using the automated system? A: Depending on the panel size, it takes approximately one to two hours for a panel to be fully assembled.
  2. Q: What is the cost comparison between upgrading the old machine and buying a new one? A: The upgrade cost was around 10% of the expense of purchasing a new machine with similar functionality.
  3. Q: How does the system handle panels of different thicknesses? A: The clamps of the automated system self-adjust to hold panels of varying thicknesses securely.
  4. Q: Is CAD or CNC experience required for operating the upgraded machine? A: No, the control system operates from an Excel spreadsheet, eliminating the need for CAD or CNC expertise.
  5. Q: Can the automated system accommodate panels of different sizes? A: Yes, the system can accommodate panels of varying sizes within its work envelope.

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