Mechanical Technology June 2016

⎪ Automation, mechatronics and electro-mechanical systems ⎪

Simple automation: MPS production and an ultrasonic bath

These two success stories, described below by Jaco de Beer, a project engineer for Tectra Automation – a member of the Hytec Group of companies and the authorised distributor for Bosch Rexroth automation products – demonstrate the diversity available from this leading local automation solutions provider.

B EKA Schréder has increased its average production rate of LED luminaires by 50% through four new semi-automated manual production systems (MPS) sup- plied by Tectra Automation at its Olifants- fontein factory. The production line replaces a more batch-oriented configuration for the as- sembly of four recently designed LED light ranges used for lighting streets, highways and outdoor facilities. Tectra Automation supplied an MPS for each range as part of a turnkey project that included the design, supply, factory ac- ceptance testing, integration and com- missioning of the MPS, as well as its electrical installation. Each of the four production lines con- sists of five workstations, connected in a 10 m lane of aluminium rails and runner blocks where operators assemble the luminaire units on specialised aluminium trays. Tectra Automation fitted these trays with specialised mounting blocks that secure the units during assembly. At the end of the production line, units are removed from the tray for quality inspection. The tray then enters a low- ering station, where it is automatically

lowered to a return line and delivered to the front of the production line. Trays can accumulate one behind the other before being fed to the top, one by one. “By improving the efficiency of movement and flow of production within the facility, the MPS has enhanced the productivity of as- sembly, with improved wo r kman sh i p and product quality,” ex- plains Jaco de Beer, project engineer, Tectra Automation. All production line lifting and lower- ing requirements are achieved through a maintenance-free pneumatic system. Tectra Automation supplied valves, pneumatic actuators, air supply units and filtration systems. “We used the new Aventics AV03 valve to control each pneumatic cylinder,” De Beer explains. “This valve is ideally suited to these types of applications because of its compact, neat, all-in-one functionality.” BEKA Schréder’s four white-light LED ranges, OMNIStar, LEDlume-maxi, LEDlume-midi and LEDlume-mini, de-

liver exceptional colour rendering and visibility over a long lifespan, and are highly efficient in energy consumption. “Such is the success of the products that they will soon be exported to Europe,” De Beer concludes. The MPSs were installed over a three- week period at the end of 2015, with other necessary changes to production prepared and implemented during the year-end shutdown. Ultrasonic bath: engineered for accuracy Tectra Automation has also designed and

Side view showing the assembly line. The inclined level of the MPS is used to return the assembly trays to the first workstation following the delivery of a completed light to quality inspection at the end of the line. Inset: The 10 m MPS lanes each consist of five workstations, where operators assemble Beka Schréder’s LED luminaires on specialised aluminium trays.

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Mechanical Technology — June 2016