Contained robot boosts MechCaL's fan production

Published: 20-Sep-2016

The designer and manufacturer of industrial fans has constructed a dedicated Robot Cell to contain the dust and to protect the factory environment

South African designer and manufacturer of industrial fans, MechCaL has invested in cutting edge technology to enhance manufacturing productivity and performance.

It has purchased a Motoman robot from Yaskawa to carry out several vital tasks that will enhance the design of its advanced mining ventilation fans.

Production environment requirements in the field of mining ventilation are very high. Not least, strict cleanroom criteria, testing facilities and staff safety present several industry specific challenges.

In addition, to survive in the highly competitive mining market, companies need to maximise production efficiency and minimise costs.

The robot has been installed within a newly constructed ‘robot cell’ at MechCaL’s manufacturing facility in Pretoria.

MechCaL’s design and manufacturing team will use the robot for cutting the plugs that are required for producing moulds and also for cutting moulds directly.

The robot’s multi-station capability will be used to trim and drill composite fan parts with greater accuracy and faster output compared to the previous manual process that was carried out using jigs.

Manufacturing large three-dimensional blade shapes and structures requires large moulds. Previously, MechCaL outsourced the manufacture of the necessary mould plugs to suppliers that used CNC routers or milling machines.

Having this capability in-house, says Michael Minges, Principal Engineer and Director of Operations at MechCaL, means that overall production costs can be lowered.

In addition to increased efficiency, the robot’s capabilities will boost the quality of MechCaL’s finished products.

To accommodate the robot within the factory to the required industry standards, MechCaL constructed a dedicated Robot Cell.

The cell will contain any excess material that the robot creates during its operations, such as e-glass, carbon dust, wood flakes, etc., to protect the factory environment.

Containment of these particles means that they can also be extracted and disposed of more efficiently.

According to Minges, the moving robot arm also exerts considerable force when in operation and could injure someone if not contained.

The cell therefore has automatic shutdowns linked to the opening of access doors to maintain the safest possible working environment.

Yaskawa produces a wide range of Motoman robots, some with ISO class 7 rating are particularly suitable for operation in environments with strict hygiene requirements.

These can have antistatic paint to reduce the settling of dust particles, and a smooth surface makes for easy wash down and resistance to regular cleaning agents.

You may also like