How customize a filling machine handle the filling of different ratios and viscosity of AB glue?
1.Case Background for AB Glue Filling Machine Technical Challenges
The client is based in Dubai, United Arab Emirates. His epoxy resin material A is paste-like, while material B is liquid. The materials come in two ratios: 3:1 (1000ml) and 4:1 (940ml).
To reduce costs, he aims to fill both ratios on a single workstation while requiring two separate filling and capping fixtures.
Other manufacturers in the industry fall into two categories: some simply lack the technical capability to develop feasible solutions and only offer two basic units; others can perform integrated design, yet the cost of their single filling machine matches that of two separate units. Consequently, within the industry, the most common approach for handling different filling volumes or even varying ratios typically involves configuring two separate machines. For first-time buyers, making this trade-off is challenging.
2.Maxwell's Advantages Over Competitors
Previously, for clients requiring different filling volumes but identical filling ratios, we would configure one, two, or even three filling systems integrated into a single unit. Naturally, compared to a single automated filling and capping machine, this approach demanded greater design expertise and industry experience. Past cases have proven our significant success in such integrated designs, earning excellent feedback from clients.
Thus, we embraced an even greater technical challenge to meet the client's ideal configuration: acquiring a single machine to handle the filling and capping processes for products with different viscosities, filling volumes, and filling speeds.
3.Technical Challenges Involved in the Design of a Two-in-One Dual-Component Filling Machine
●(1) Independent Lifting
Requires two sets of independent lifting fixtures.
●(2) Independent Programming
Also necessitates rewriting two separate programs within the Siemens PLC system.
●(3)Budget Optimization
Simultaneously ensuring the cost of one machine is lower than two machines, as budget constraints are a key reason the client insists on a single system.
●(4)Independent Material Pressing
The differing flow properties of the two materials necessitate separately designed pressing systems.
4.Detailed troubleshooting process and customized solutions
(1) A component high viscosity material filling system
For the paste-like Material A, we selected a 200L press plate system for material conveyance. Full drums of adhesive are placed onto the press plate base, which conveys the adhesive to the adhesive pump. Servo motor drive and metering pump interlock control the adhesive ratio and flow rate, coordinating with the automatic adhesive cylinder fixture to inject the adhesive into the cylinder.
(2) B component liquid material filling system
(3) Heating system
Based on the customer's additional requirements, a heating function has been added, featuring high-temperature-resistant piping and heating elements integrated into the pressure plate.
(4) Independent filling systems
For adhesive filling, we have established two independent filling and capping units. No tooling changes are required during operation. When switching materials, only the material tube interfaces need to be replaced, along with cleaning the pressure plates, thereby reducing labor costs.
(5)Independent programming systems
For PLC control operations, we have also developed entirely new programming, implementing two independent systems to ensure simple and efficient operation for workers.
