Projects
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TURNKEY AUTOMATION PROJECTS & MACHINE BUILDING The
following list includes projects we have done for national and international
companies. Project scope/prices are included as indication of project sizes. BMW
Motor Company -South Africa a)
FINISHING LINE AUTOMATION and CHARGE LINE UPGRADE- BMW The finishing line at BMW was part of the automation process we did with an alliance company. It involved two systems. The first is the sequence and line flow control system with PLC and wiring controls. The second was the charger conveyor control and sequencing upgrade. PROJECT
SCOPE – R280 000-00
b)
MULTI-CAMERA MACHINE VISION SYSTEM This
system was installed and integrated with 8 cameras for a complete quality check
of the BMW 325/8 Engines for block and part presence (valves, springs…),
placement (Skew or not aligned), and quality (bent, cracked, size…). Before
this system was installed, BMW blew up an average of 3 engines a month on their
engine test bench due to human oversight. PROJECT SCOPE – R245 000-00CHAMPION
SPARK PLUG (Coopers Automotive - South Africa) Projects for this company stretched through 20 months on seven machines. We built one complete new spark plug feeder/assembler and completely retrofitted/overhauled 7 older machines. ALLAN BRADLEY PLC’s were specified and used on all machines. We also saw to the pneumatic and hydraulic upgrades where applicable. The customer did all mechanical upgrades and customizations in their fully equipped tool room. A short description of some of the work done: a.
b.
Plug tamper complete electronic PLC, SERVO, HYDRAULIC & PNEUMATIC
retrofit and modification. The robotic arms, 16 station rotary table and special
high speed/impact hydraulic rams were overhauled with a complete new PLC system
included 85 I/O, High Speed counter Module and Allan Bradley 550 Graphic
operator interface. One complete product each 0.75 seconds.
c. The
Isolator assembly machine were the largest of the retrofits. The PLC had 188 I/O
with Analogue and counter units running two DH+ networks with twin AB 550
Graphic interfaces. Resistance unit, strain gauge and sensors had to be
integrated. The pneumatic system was also replaced to accommodate the cycle time
of 0.4 seconds per part. THE
SCOPE FOR ALL PROJECTS HERE WERE +- R840 00-00 LABOUR
& MANUFACTURE COSTS OF R1 350 000-00 was saved due to the new and upgraded
machines over the 20-month period and similar savings since completion. ROBERT BOSCH SA a)
LACQUER DIPPING MACHINE We designed, built and commissioned this complete machine end 2000 as a turnkey project including the design, frame, machined slides, component fixtures, Teflon fluid pump/tubing and special valves. This included a PLC, MMI operator display, keypad and a proportional dipping system (Pneumatic), with fluid lacquer temperature control, viscosity control, and auto thinners cleaning sequence. PROJECT
SCOPE – R265 000-00 OTHER
PROJECTS DONE FOR BOSCH
FORD
MOTOR COMPANY SA (SAMCOR) This project system took 3 months and involved a full installation on a lubrication distribution system through the plant over 500 meters. Included was 1600 meters of hydraulic piping, 5 Lube pumps an ASI (Actuator sensor Interface) PLC electronic network, starters, stands, tanks, wiring, and instrumentation all done to FORD PROJECT SPECIFICATION STANDARDS
THE ABOVE PROJECT SCOPE WAS– R185 000-00
TOTAL
SCOPE R36 500-00
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New
rotary/Linear parts feeder complete with PLC-Robotic Control. (We designed,
built the complete machine and imported the rotary & linear parts feeders,
strain gauges and amplifiers from the U.S.A and U.K
