Spray Trigger Start Device

Summary

Background

• The biggest challenge of this project stemmed from the cost limitations set by the customer. This meant that a typical independent thread starting device for each bottle cap would be difficult to implement to stay under budget within the allocated project schedule. With this challenge in mind, DAPR designed a custom belt-drive to initiate the cap threading of four bottles at a time. This four-up process was selected through detailed timing studies to maintain the throughput of the existing manufacturing line. Independent compliance was built into each bottle position to simulate independent control so that each bottle cap did not affect the others during the belt drive operations. Maintaining cap orientation was crucial to the success of the project. The old ‘capper’ worked well when caps were oriented appropriately. However, if caps were slightly misplaced at an angle, it would often fail, causing misalignment of the threads and cross threading when torqued down. Prior to DAPR’s engagement, even if caps were carefully placed in the proper orientation at the start, by the time they reached the capping device, the bottles had been jostled against each other enough to knock the caps out of alignment. To address this issue, DAPR captured the caps with custom guides, and then used torque starting techniques to ensure orientation while threading caps on the bottles. Utilizing the new machine, the client was able to improve quality assurance, reduce man hours without the need for a checker, and increase the uptime of the machine without spills occurring. The culmination of these improvements therefore increased production.
• DAPR had to integrate automation equipment within the constraints of the existing equipment with a customized automated robotic solution. Limitations such as dimensional requirements of the existing machine footprint, precise timing & spacing of the customer’s products & the existing capping process added complex challenges. This required a high level of “out-of-the-box” creativity coupled with solid engineering best practices to produce a quality solution. The entire machine was custom-built to fit within our client’s existing manufacturing line, as there was not enough space, nor the capital from the client to install a completely new system.
• To prove the feasibility of the innovative belt-drive solution, significant prototype testing was performed. The design was created to be easily adjustable so that the ideal settings could be dialed in. The prototype testing phase was crucial in ensuring that the design would work as intended to optimize the machine’s performance.