1. MU 7 Mak Fu Shun Kong Yau Choi Lee Man Kit Poon San On Zen YKK Project: Automatic adhesive machine

2. Introduction YKK Hong Kong Limited established in 1966. YKK Hong Kong Limited established in 1966. As a subsidiary of YKK Corporation. As a subsidiary of YKK Corporation. One of the biggest corporation in producing and selling zippers. One of the biggest corporation in producing and selling zippers.

3. Introduction Co-operate with YKK Co. to design an extended automatic adhesive machine. Co-operate with YKK Co. to design an extended automatic adhesive machine. Existed Automatic adhesive machine

4. Introduction YKK Co. now can only stick the tape onto the middle region of the box. (Easier task) Our job is to design a machine to stick the other two sides. (More complicated)

5. At this region, here are the 2 adhesive machines given from YKK, which are not shown to reduce complicated drawing. The cylinder with a plate to push the box forward. The result are like above, only half is attached! Initial Design 1

6. Each set has 2 cylinders, first the horizontal ones extends to touch the box. Initial Design 2

7. Initial design 2 Vincent

8. Once the box press the senor, cylinder will push the box to the second conveyer. Therefore, the box can change the direction. Sensor

9. Then the box will pass through the sticking machine.

10. Initial Design 3 Eddie

11. Initial design 3 brush smoother

12. Initial design 4 By Jason

13. Initial design 4

14. Intermediate Design

15. Step 1 : To push the box into conveyor

16. Step 2 : Stick adhesive paper on the box

17. Step 3 : Rotational cylinders press the adhesive paper firmly

18. Final Step : Cylinders press adhesive paper firmly

19. Different Size of boxes

20. Final Design

21. New Design Old Design The different between new design and old design

22. Old Design New Design

23. Working Mechanism

24. Main support : Hold the upper support and adjust the height for different boxes size

25. Parts : Cylinder Linear Bearing

26. Upper Support : Hold the all the main part of adhesive machine and adjust the wide

27. Cylinder and Linear bearings

28. Hold all the main parts

29. BOM Two Adhesive machines Two Adhesive machines 9 Cylinders 9 Cylinders 6 linear bearings 6 linear bearings 22 Sensors 22 Sensors 1 PLC model 1 PLC model 1 Touch Panel 1 Touch Panel Long/Uncut Profiles, Cables … Long/Uncut Profiles, Cables …

30. Planning of works 1. Profiles cutting & Surface finishing ~1.5 weeks (due to change of design) 2. Holes drilling ~5 days 3. Construction of frames ~2.5 days 4. Mounting parts for cylinders installed on frame ~2 weeks 5. PLC & Touch Panel Programming learning ~ 1.5 days 6. Simens PLC Programming Simulation and testing ~ 3 days 7. PLC programming drafting ~1.5 days 8. PLC programming design ~3 days 9. Touch Panel programming design ~2.5 days 10. Testing & Debugging on working condition of touch Panel connecting with PLC. ~2 days 11. Installation & connection of PLC, Touch Panel and solenoid valve using cables ~3 days (PLC & TP finished by 24 June.) 12. Website making ~1.5 weeks, continuously 13. Modification on the design ~1 week 14. Whole machine testing and debugging ~2 days

31. Machining Machining

32. Machining Workshop Milling Machine - holes drilling - surface finishing Milling Machine - holes drilling - surface finishing Sawing Machine -cutting Profiles Sawing Machine -cutting Profiles

33. Milling Machine Increase the smoothness of the surface Increase the smoothness of the surface Rotating speed Rotating speed Cooling liquid Cooling liquid

34. Milling Machine Drilling holes Drilling holes Milling Surfaces Milling Surfaces

35. Milling Machine Drilling holes - Center Drill - corresponding dia Drill, E.g. 6 mm dia Drill (different sizes) - 26-mm dia Drill - Boring tool Drilling holes - Center Drill - corresponding dia Drill, E.g. 6 mm dia Drill (different sizes) - 26-mm dia Drill - Boring tool Cautions Cautions

36. Milling Machine Milling Surfaces - Milling Cutter (different sizes) Milling Surfaces - Milling Cutter (different sizes) Cautions do not mill deeply & too fast Cautions do not mill deeply & too fast

37. Milling Machine Products Products

38. Parts

39. Sawing Machine Cautions - adding cooling liquid Cautions - adding cooling liquid Increase the smoothness of the surface - cutting error  shorter  milling surface

40. NCM Workshop Electro-Discharge Machine (EDM) - Wire Cut Electro-Discharge Machine (EDM) - Wire Cut (the shaft is too hard) (the shaft is too hard) Cautions - Flammable Liquid Cautions - Flammable Liquid

41. Difficulties in Machining High Precision -squareness -same length High Precision -squareness -same length Some holes are too big to drill Some holes are too big to drill Linear bearing shaft - too hard (strong steel) Linear bearing shaft - too hard (strong steel) Thread not matched Thread not matched - Straight Adaptor does not fit cylinder provided by YKK - Straight Adaptor does not fit cylinder provided by YKK

42. System Control Pneumatics /Cylinders Pneumatics /Cylinders Connect to output devices Both Input & Output Sensor Connect to input devices Connect to Touch Panel Solenoid Valves

43. Why use PLC? Cost effective. High stability and flexibility. Can work under adverse environment. Easy programming. Plenty input and output addresses, moreover extendable.

44. Input & Output addresses 24 Input Addresses (All used) 000: Touch Sensor 001: Retraction sensor of Long Cylinder. 002:Extension sensor of Long Cylinder. 003-010: Built-in sensors of Cylinders. 011: Big Box button. 100-107: Built-in sensors of Cylinders. 108-109:External Photoelectric Sensor. 110: Start Button 111:Reset Button 16 Output Addresses: (10 used) 1000-1100:Cylinders 1101: Blocking unit

45. Input/Output Table for PLC StepPre-conditionPractical Output 1110(start) pressed000-Touch sensor (TS) is turned on and ready for use. 2000 is triggered by box 1000(LC) is set, 1001-1005 are reset. 3108 (RS) senses from 0 to 1 when box passes in 1001,1002 are set (rotate 180  )

46. PLC Programming

47. Why use Touch Panel? Can emulate buttons & switches easily. Can emulate buttons & switches easily.  Reduce complication.  Reduce complication. Can emulate lights. Can emulate lights.  Check output status.  Check output status. Shows the input & output status. Shows the input & output status.  Check the operating process.  Check the operating process. Easy Programming. Easy Programming.  High efficiency.  High efficiency.

48. Touch Panel Programming Press Start button  sensors triggers, machine works on itself.

49. Status of Sensors & Cylinders LC: long cylinder RC: rotational cylinder BC: Brush cylinder boxes counter: use Sensor to sense the box, and add 1 each time.

50. Testing Test on PLC Program Use Dip-Switch to emulate the sensors and buttons. Test on Touch Panel with PLC Test if PLC reacts exactly to the commands of Touch Panels.

51. Testing Test on built-in Sensor with PLC The retraction sensor reacts and switch on the input 000 of PLC. Both lights’ ON. Test on Solenoid Valve to control the gas flow & direction of cylinders.

52. Video Clips

53. Conclusion We have learnt We have learnt - How to apply our knowledge & study on practical tasks. - How to communicate and co-operate with companies. - Dealt with variable difficulties.

54. Conclusion - Better understanding on IC workshops. - How to put ideas into reality. - Importance on effective planning of work. -Many mechanical knowledge, technological products, and programming. -Many mechanical knowledge, technological products, and programming.

55. The end