Automation Filling Bottle at Programmed Intervals, Move down Line, and Maybe Label 1

[mechanicalchad]

I have trucks that unload fluid into our system at some pressure and I would like to take samples throughout the unload process to characterize that load. Trucks often unload one after another without an operator present to change sample bottles. The fluid varies in type, and sometimes there will be lots of solids and gels in it which can plug small orifices. We charge on contaminants though so it's important we get these in our sample.

Does anyone know of a cost effective, off-the-shelf solution, or components, that is available that basically opens and closes a 1" valve at programmed intervals while a pressure switch is on, filling a bottle roughly the size of a pop bottle, and then once the pressure switch is off, move the bottle down the line so the next bottle can be filled? I'm thinking I would need room for about 20 bottles a day per unloading area and then have the operator reset it daily. Moving the bottle down the line is a luxury though, and I would weight that against the cost of having an operator change out bottles.

Another luxury I would also like to know if it exists, is a system that could label these bottles based on some very simple hmi data input.

If anyone knows of such an off-the shelf system, or knows what components could be put together to form this system I would greatly appreciate a point in the right direction!

Thanks,
Chad

 

[mcgyvr]

Sounds like a fairly simple/fun system to put together.. I doubt anything off the shelf will do exactly what you want.
A plc to determine when to sample and to control a valve and a simple conveyor setup

 

[djs]

Various companies make sampler systems. None are low cost.

 

[mechanicalchad]

Yeah I think putting it together ourselves is probably the way to go then given the high costs of the off-the-shelf systems.

Any recommendation on a cheap and simple PLC? Preferably one I can program using Visual Basic. Also, I was thinking it would be handy to have a cardlock (maybe RFID instead of mag strip), any recommendations on a make or model?

 

[BrianE22]

Have you looked at using a robot? There's tons of used ones out there.

 

[mechanicalchad]

I just assumed they'd be expensive and complicated haha, but if they are cost effective and meet my my needs I'm all ears! Do you know what type or make/model I would be looking for, and a good posting board for used equipment?

Thanks,
Chad

 

[BrianE22]

I bought a used Fanuc S10 robot about 5 years ago and I use it to feed parts in and out of a CNC lathe. I got it on Ebay for about $5k. Do a google search on used robots and you'll find plenty of dealers. Ask them to recommend a minimum configuration. You'll need to give them the working envelope. If going for a used robot, I'd recommend getting one that has a controller that is still being supported.

The Fanucs use a programming language called Karel. It's very similar to Basic and you'll be able to pick it up quickly.

You can buy end of arm grippers from a company like Schunk. You'll have to make special grips to grab your bottles.

My robot came with 8 digital inputs and 8 digital outputs. Make sure whatever you buy has those (I think they're pretty standard).

What's nice about a robot is that it's easily reconfigured if your line changes in the future.

 

[FACS]

Before you decide that tings are too expensive, why don't you calculate what the system is worth to you.... then decide how much you are willing to spend on it.


Charlie

http://www.facsco.com