Automatic Punching and Film Pasting Machine

With the development of technology, automation has become an important means of improving efficiency in today's manufacturing industry. Our company has developed an automatic film pasting machine based on the demand for automated production lines, hoping to eliminate manual labor through automated equipment. This is particularly important in the era of labor shortage in the industry.   As the manufacturing industry seeks to upgrade and move towards Industry 4.0, automation equipment combined with process data collection is an important foundation for improving process quality. It not only improves efficiency but also collects various production data. The collected big data can be used to guide production decisions, optimize equipment configurations, predict faults, and achieve smart manufacturing after being analyzed and processed.

Detailed Operating Process of Automatic Film Pasting Machine

The operation of the automatic film pasting machine is fully automated, including feeding, punching, feeding, film pasting, full inspection, and T&R packaging. The integration and connection of the vibration plate alignment, punching mechanism, precision feeding mechanism, film pasting mechanism, automatic optical detection system (AOI), and PLC programmable controller signals achieve continuous automated production from feeding to film pasting to output packaging.

The following is a detailed process description:

1. Automatic Feeding SystemThis equipment uses a vibration plate feeding system. Simply put the metal parts to be punched and pasted into the vibration plate. By controlling the vibration frequency, the parts are scattered and finally sent to the flat conveyor for alignment, achieving automatic, continuous, and uninterrupted feeding without manual intervention.
   
   
2. High-precision punching mechanismThe punching process is quickly completed by the punch. The punch and mold are designed for easy disassembly and replacement of punch consumables. Together with the upper and lower precision guide pillar mechanism, high-precision punching size and stable quality are achieved.

3. Precision Feeding MechanismIt uses a 12-axis mechanical divider's disc mechanism. The variable frequency motor controls the adjustable speed to drive the divider mechanism to accurately reach the processing position. The positioning accuracy is extremely high and stable in production.
   
   
4. Automatic Film Pasting MechanismThe film is automatically moved to the bonding position by a small segmented mechanism with positioning beads, and the film is accurately attached to the surface of the part using a vacuum suction cup. The entire process does not require manual operation.

5. Vision Inspection SystemThere are two vision recognition camera lenses in total. After punching and film pasting, the parts will enter the AOI system for judgment. The industrial-grade camera lens is used with light sources to analyze each part through image detection software to detect hole size position and film pasting symmetry. If there are any NG defective products, a signal will be provided to make the mechanism place the parts in the NG slot.
   
   
6. T&R Packaging System
   The automatic arm transfers the film pasted good products to the T&R packaging system to complete automatic cutting and packaging and can input the required quantity to complete reel packaging. This achieves neat and orderly packaging of finished products for automatic production in the next process.
   
   
7. Human-Machine Interface SystemIt adopts a touch screen and graphical human-machine interface. Operators can complete all machine start-up, stop, parameter setting, etc. through simple touch options without any programming knowledge. It can also display machine running status and statistical information.

The Advantages of the Automatic Punching and Film Pasting Machine

1. Efficient Automation Production
   This equipment achieves fully automated production from feeding, film pasting to output packaging without manual operation. Compared with the traditional manual operation mode, it greatly improves production efficiency. A single machine can process hundreds of parts per hour.
   
   
2. Precise Quality ControlThe punching size and symmetry after film pasting are within the tolerance and meet the drawing specifications of the finished product. The machine vision technology monitors the product punching and film pasting positions in real-time and immediately isolates the detected defective products to ensure that the output products meet the standards. It avoids the risk of missing inspection in manual inspection and achieves 100% full inspection production of parts.
   
   
3. Processing and Feedback of Process DataDuring the production process, the AOI system automatically generates inspection data records in the computer in CSV format, including data such as the size and symmetry of parts produced on the production date and time. All data during equipment operation is automatically recorded, counted, and analyzed by the system and output in the form of reports, providing a basis for product traceability and process optimization in the later stage.
   
   
4. Easy Operation and MaintenanceThe graphical human-machine interface and modular structure design enable operators to use and maintain the equipment without professional skills, greatly reducing production and maintenance costs.

 Precautions

1. Pay attention to whether the environmental air pressure is sufficient during the production process. Due to multiple vacuum detection systems, the equipment relies on air pressure sources, and it is recommended that the value be greater than 5kgf.
   
   
2. The punching is a consumable item. In this system, there is also a punching counting system for the punching part. As long as it reaches wear, it will automatically stop, so spare parts for punching are very important.
   
   
3. Because the products produced by the equipment are used for electronic components, it is necessary to produce them in a clean room with a certain level of cleanliness to avoid residual debris caused by external factors.
   
   
4. The use of AOI automatic optical inspection system achieves 100% full inspection production of products, which is also extremely important in environmental lighting. It must have stable environmental brightness to avoid interference with light sources.

Summary

Layana has an excellent automation R&D team that can design and develop automation equipment. From scheme design to mechanism development and verification debugging, we provide more customized manufacturing and processing solutions. We also work with software equipment suppliers to develop more intelligent automation equipment.

In the future, Layana will continue to leverage the technical advantages of our internal R&D team and our long-term part production capacity to provide customers with more automation and intelligent solutions. We are confident that with innovative technology and services, we can bring higher production efficiency and product quality to customers. We look forward to establishing a long-term cooperative relationship with you and jointly moving towards the era of Industry 4.0.