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Ergonomics Meets Dispense

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Assembly solutions often require an array of different equipment to get the desired result. In this case study, Air Power was able to design a fully ergonomic dispense solution for this customer.

 

Customer

 

Manufacturer of HVAC Equipment

 

Challenge

 

This customer was planning an expansion that included adding 2 additional assembly lines for panel foaming. They wanted to have a more robust Gantry System, contrary to solutions discussed previously with other distributors. Air Power’s ability to integrate the Material Handling portion of this project along with the Dispense/Fluid Management system allowed us to be the sole solution provider the customer was able to find through the initial quoting phase. After digging into the project, the customer realized our potential and requested the Mix, Meter, and Dispense System to supply two separate assembly lines, thus adding more complexity to both portions of the MOVE project. Factors like pressure loss, high-pressure piping, distance, ergonomics were key when bringing this project from theory to paper to real life.

 

Air Power Solution

Our team was able to design a custom solution that utilizes a Unified Dual Cantilever Overhead Rail System, paired with a Hennecke High-Pressure Metering Machine designed to dispense the full range of rigid foams and flexible foams. This dispense system controls 2 mix heads to fill panels with a Polyurethane Foam on 2 assembly lines. This system pumps the foam through high-pressure hoses mounted overhead with an Ingersoll Rand Suspension Balancer and Z-Servo Balance Control.

 

Ergonomics Meet Dispense

Results

This system has the ability to have cross-lateral movement spanning the entire workstation, pump foam throughout the 1000+ feet of piping/hoses, ergonomically sufficient enough to navigate the 100lbs mix heads North, South, East, West with minimal effort, and produce foam with the touch of a button. We were able to deliver all of the key factors with a combination of our vendor support, customer communication/guidance, and our internal resources to deliver a unique one-of-a-kind turnkey solution!

 

Ergonomics

 

Ergonomics_HVAC_ASSEMBLY

Ergonmics Dispense Assembly Solution

 

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Ergonomics Meets Dispense

Air Power Puts the Graco ProMix PD2K to the Test with HB Fuller

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Air Power Manufacturing Solutions Put PD2K to the Test with Graco and HB Fuller

 

The customer is switching to Swifttak 4431 Heat Reactivated Water Based Adhesive, a two-component adhesive, for better product quality. They need a system to effectively mix and spray the 2K adhesive. The Graco PD2K is the only 2K system that can effectively handle the Swifttak adhesive due to the industrial pump based unit which allows for operation in either flow or pressure made.

More about Graco ProMix PD2K System

More about Graco ProMix PD2K System

The ProMix PD2K mixes the material close to the gun so the flush zone is significantly smaller. This allows customers to use less paint, spend less on disposal costs and allows for faster color changes. And because there is limited mixed material in the system, the ProMix PD2K is ideal for short pot life materials. It is also compatible with acid-based materials.

Graco has specific ProMix proportioners that are designed to manage tough acid catalyst applications like cabinetry and bar countertops. The corrosion resistance fluid section, plus the smart fluid plate with 316 and 17-4 SST catalyst sections, can easily handle strong acid catalysts.

 

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Graco ProMix PD2K

Graco Electric Fixed Ratio (EFR) System

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The Graco Electric Fixed Ratio (EFR) system is a meter, mix and dispense system for two component sealant and adhesive delivery. Ideal for applications requiring precision dispense, the EFR provides superior control over material and dispensing of gaskets, beads, shots and potting applications. Trust in the EFR, which is accurate, versatile and easy to use.

The Graco Electric Fixed Ratio (EFR) system

 

  1. Advance Precision Driver

    • Powerful driver reaches up to 20 cycles per minute
    • Precise encoder that assures low flows and small shots consistently
    • Direct pump control
    • Limited maintenance needs

 

  1. Industry Proven Z Pumps

    • Multiple Ratio options
    • Only the seals are wear parts
    • Abrasive resistant version
    • Mechanically linked pumps offer ratio assurance

 

  1.  MD2 Valve

    • Adjustable snuff back
    • Mixing at tip of the gun, limiting purge material waste
    • Multiple seal combination for material compatibility
    • Available in 1:1 to 10:1 for wide ratio applications
    • For manual or robotic applications

 

  1. Advanced Display Module

    • Easy to use interface
    • Possibility to have it completely integrated
    • Communication Gateway Modules: EtherNet/IP. DeviceNet, PRofibus, Profitnet