Automation at ETI Proplast : Production Line Development

Automation in manufacturing companies is crucial for producing high-quality products, and we introduce it into processes where operations are repetitive. This ensures faster and more precise production, relieving workers from repetitive movements, harsh working environments, heavy lifting, or performing intricate quality checks. A significant aspect of automation is the traceability throughout the entire process, allowing for real-time product monitoring, and recording of technological parameters.

Automation has evolved over time, with increasingly complex components becoming available over the past two decades. Robots and modern servo systems are now indispensable, with growing integration between mechanical and electrical engineering. For high-level automation, we need mixed teams of mechanical engineers and electronics experts, a practice we successfully implement at Proplast.

Automation Department at ETI Proplast

Our automation department consists of mechanical engineers and electronics experts. The process of developing a new machine or an assembly line begins with close collaboration with clients, typically technologists from ETI. During the concept phase, we align on technological requirements, assembly and inspection operations, control systems, and material flow. We also consider spatial constraints in the workplace to accommodate the machine’s installation.

The construction phase starts with design, which is a team effort involving mechanical engineers, electronics experts, and technologists. Using CREO software, we first create a rough concept, outlining the primary components and defining the material flow and technological processes. Once the design is finalized, we produce the necessary technical documentation, bills of materials, and control schematics.

Automation of NV and VV Fuses

In the past year, we have focused heavily on automating the production of NV and VV fuses. We are in the final phase of creating a new assembly line for NV00C fuses with aluminum covers.

We also upgraded the VV fuse assembly process, previously relying on manual operations. Given their larger size and ceramic composition, VV fuses are challenging to assemble manually. The goal was to minimize manual labor and increase automation. A new device was developed for automatic winding and welding of fuse elements onto ceramic holders, significantly enhancing efficiency.

Advanced Solutions for Tube Flanging and Sand Filling

As part of the automation process, we also developed a machine for simultaneous double-sided tube flanging, which automates the entire process. This device adjusts automatically to the geometric characteristics of the fuses. Additionally, an integrated labeling system applies a 2D code to each fuse, encoding essential product information.

One of the most complex machines in this automation process is for sand filling the fuses. The device features a six-axis robot that transfers the fuses through various stages, ensuring precise and flexible operation for different fuse types and dimensions. This machine communicates through an MQTT protocol, aligning with IoT 4.0 standards, and enabling real-time data exchange for production monitoring.

IoT and Industry 4.0 Integration

The automated line is equipped with local control systems for autonomous machine operation. An industrial computer connects all the machines, facilitating data exchange both internally and with global networks. Following Industry 4.0 guidelines, we use the MQTT communication protocol to send real-time data to a database. This structured approach allows for easy scalability and integration with other systems, meeting both client demands and IoT standards.

The result is a flexible, efficient, and repeatable process that positions us at the forefront of industrial automation, continuously driven by the latest advancements in technology.