Foam Sorting Automation

Precise Singulation and Handling of Non-Rigid Porous Material

The first and most crucial challenge involved the precise singulation and handling of non-rigid, porous materials from a stacked configuration without incurring any damage to the parts. Traditional pick-and-place technology proved inadequate in dealing with these delicate materials as they often became distorted or damaged during handling. To address this, Re:Build DAPR Engineering leveraged vacuum cups to gently pick and place the parts. Determining the optimal flow rate for the vacuum cups was achieved through extensive proof-of-concept testing, ensuring the safe and precise singulation of the porous material.

Redesigning the Tester and Press for High-Speed Operation

The existing machine had been using a repurposed arbor press for its operations. However, this press was found to be unsuitable and prone to cracking under the demands of the application. In response, Re:Build DAPR Engineering initiated a comprehensive redesign of the press, creating a robust weldment capable of withstanding the required pressure without the risk of fracture. Furthermore, Re:Build DAPR optimized the design of the tester by reducing its stroke, leading to a significant reduction in cycle time and a substantial improvement in production efficiency.

Integration of Automation Within Existing Equipment Constraints

The project’s process design presented a unique set of constraints due to the dimensional requirements of the existing equipment. To tackle this challenge, Re:Build DAPR Engineering demonstrated an exceptional level of creative problem-solving while adhering to sound engineering principles. This involved the development of a customized automated robotic solution that effectively operated within these constraints, highlighting the team’s ability to think “out of the box” while maintaining engineering integrity.

Seamless Loading and Unloading for Continuous Testing

One of the fundamental requirements for the machine’s design was to allow the client to safely load and unload products without disrupting the testing cycle. This aspect necessitated meticulous attention to detail and precision engineering to ensure a smooth and uninterrupted testing process, ultimately enhancing the overall efficiency of the system.

Successes

The successful resolution of these challenges underscores Re:Build DAPR Engineering’s commitment to delivering innovative, effective, and efficient solutions tailored to our client’s specific needs. The project exemplified our team’s capacity to surmount complex engineering hurdles, showcasing our company’s exceptional capabilities in the design and construction of advanced automated machinery.