Banelec was recently approached by a customer in need of a complete machining cell solution for the continuous manufacture of ejector seat shafts. Tasked with designing, constructing, creating software for, installing, and commissioning the entire system, Banelec rose to the challenge and delivered spectacular results that have left the customer delighted.
The customer, a prestigious aerospace ejector seat manufacturer who had been relying on manual labour for decades, was venturing into the realm of robotics for the first time. Banelec was entrusted with designing both the electrical and mechanical components of the project, as well as developing the necessary software to bring the system to life.
The machining cell designed by Banelec features a multi-process operation that streamlines the manufacturing process. A CNC machine is used for the initial procedure, after which the component is unloaded by a robot and placed on a custom 2-tier conveyor system. While the first component is being processed, another CNC machine completes the final procedure, and the robot seamlessly transfers the component to the upper tier of the conveyor. This process continues in a continuous loop, ensuring efficiency and precision throughout the manufacturing process.
One of the key challenges in the project was to optimise space and cost efficiency. Initially, the customer believed that two robot cells would be necessary, doubling the expense and space required for the system. However, Banelec's expert engineers utilised advanced robot modelling and 3D CAD software to devise a solution that could achieve the desired outcome within a single cell using a single robot and a unique 2-tier conveyor system.
Every aspect of the design process, including the mechanical design of the conveyor system, was meticulously overseen by Banelec's team of experts. The mechanical designer developed the concept and produced detailed drawings using in-house design software, while the construction of the conveyor system was executed by skilled mechanical engineers. The entire installation process was carried out by Banelec's team, from fitting the components on-site to electrically connecting the system and ensuring proper functionality.
The successful completion of this custom machining cell project has significantly enhanced the productivity, efficiency, and safety of the customer's manufacturing process. Banelec's expertise in mechanical design and automation has paved the way for future turn-key projects, showcasing the company's innovation and commitment to delivering exceptional solutions to its customers.
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