• 13 Feb, 2017
  • Battery Manufacturing Automation

Project Description

This unit forms part of the automated production line end of line, this allows both feed back of any process errors with the lid sealing process and also can be used to capture metrics on peformance if the production control system is intregrated with ERP or other data colleciton products this unit pictured is controled by a servo to allow a wide selection of products to be tested with out any operator intervention, and using a specifically designed leak test sensor it is capable of maintaining the production rate and not impact on the quality of the test..

Other options are available for pressure testing.  We can offer both positive and negitive pressure tests, and with servo control we can profide a truely one touch change over, speeding the process of switching product and minimising the risk of operator error and machine damage.

 

 

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  • 13 Feb, 2017
  • Battery Manufacturing Automation

Project Description

When heat welding any plastic its common to end up with excess plastic spilling out from the melt area, this in some cases can be unsightly and needs to be trimmed off.

We can offer different solutions to trimming / milling off plastic excess, from a simple rotation work station where an operator manually trims off the excess using hand tools, to a fully automated 3 axis controlled unit.

We are able to design custom machinery for spru trimming including using multi axis robots where applicable for true 3d applicaitons. eg injection moulded part clean up before being used in a secondary operation 

 

 

 

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  • 13 Feb, 2017
  • Battery Manufacturing Automation

Project Description

Battery Lid Sealing:

  • heat bond two lids onto two battery boxes every 40 seconds
  • twin ball screw gearbox driven Z axis
  • split heating platten for improved tempurature control
  • oil damped stroke stops for the heater plate motion
  • duel box width compatability
  • 12 different lid sizes catered for
  • PLC control of the heating and recepe selection
  • self containted pneumatic design
  • light guards to prevent operator access during running...
  • operator loading of the carousel during normal operation with secondary light guards 

 

This machine is designed to take lids from an operator loaded magazine two at a time, and with a controlled heating cycle melt them onto the positioned boxes below. 

Its designed to handle a range of boxes from 330mm to 750mm tall in differing opening sizes

 

 

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  • 13 Feb, 2017
  • Battery Manufacturing Automation

Project Description

The Mechtek Lead Acid Battery Boxing machine:

  • can box a cell every 20 seconds
  • has a Servo controlled pushing mechanism
  • has a large long run magazine for maximum runtime without operator intervention
  • no downtime reloading with tha pull down alignment gate
  • servo controled X, Y gantry unit
  • dust extraction enclousure option
  • vacuum box pickup
  • easy change tooling 
  • 2 different box width option, or other configurations available
  • Operator HMI with manual controls, setup screens and recepe slection

all boxing and wrapping operations can be offered by Mechtek, contact us for more details on your application... 

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  • 13 Feb, 2017
  • Battery Manufacturing Automation

Project Description

Mechtek has a unique 3 elevator Cast on strap solution for the large form factor Lead acid Battery production machine.  This gives the advantage of moving the incoming and outgoing product as small a distance as possible, minimising the times spent moving product and providing as efficient a process as possible.

The three elevator system combined with mould cooling and heating control are able to offer improved cycle times and increased production rates, which will improve ROI

The unit using 4 fixed stations where the operation of loading, fluxing, casting and unloading take place,

A direct drive camco indexing unit gives a sub 2 second indexing time with very high presicion and optimised acceleration and deceleration designed in

The fluxing unit is designed to retract below the carousel, and both applies flux, and can use a secondary sponge operation to remove excess

The casting operation is supported with a heated lead bath, which can be offered with electric or gas heating, a liquid metal pump and lead level switch,

The liquid metal pump and its support facilitys are controlled by the PLC program allowing very accurate recepe setup for each product, to get the perfect process timing of heating, pre cooling and cooling

Our systems would be offered with any watercooling options as required, we can spec and supply water chillers, heat exchangers, pipework, manifilds and solinoid controle stands for cooling and recycling of the water which can be plc controled and setup from the Operator HMI

We can offer different insert placement options from basic pause, contune,  manual options, to fully automated with long runtime bowl fed robotized solutions

COS is supported by loading and unloading units, which use a servo driven puller / pusher to drive / extract the plate pack from the COS machine.

and we are able to offer different types of product clamping options from punmatic clamping with operator changable tooling, to fully automated one touch solutions where products can be switched over with minimal operator interventon..  

 

 

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  • 13 Feb, 2017
  • Battery Manufacturing Automation

Project Description

Mechtek Plate Handling:

The process of destacking a stacking plates is a challange that is often over simplified

We at mechtek dont take the task lightly and see this as the first of a set of very important stages in the production of a lead acid battery. 

If this process is right, everything else is easier, so a lot of time and effort goes into the hardware design and the software control of this part of the machine, because not only do we want to make a good machine but we want to make one thats robust and productive. 

Our philosophy is good engineering will yeald good results.  Where the plate feeders can be the same, we make them the same.  It makes good sense.  We use the same size motor on a elevator thats lifting 15 Kg as one thats lifting 250Kgs.  Its over spec you could say but it makes the spares required to maintain the machine simpler. 

Our control system for the plate feeder is far and away a leader in this field, we have auto catch up, where if the plate feeder has no plates due to it not being kept full by an operator the line will not make a bad cell or abort a cell, but it will hold station and when plates are available it will catch up and continue on taking the pressure off the upstream supply and preventing producing out of spec cells and running invalid production

The plate feeders are equipped with servo controled elevators to present the stacks at the perfect height, they have servo driven pickup arms for catchup and other control functions, and also twin contra rotating wire brushes that clean the plate tabs 

 

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