Optimizing production efficiency with automated stapling

Turner Machine Development (TMD) is a Vention Automation Partner and full-service industrial automation and material handling solutions provider. TMD’s client needed to increase production to meet a monthly demand target. However, their current manual process resulted in cycle time inconsistencies.
 
They sought an automated machine that would apply elastic staples to their products automatically and allow a more controlled production throughput.

TMD evaluated the client’s current manual process to create an automated machine that would seamlessly integrate into the existing production line. The result was a custom-designed 6-axis elastic stapling machine.
 
This machine utilizes the elastic stapler head from the previous manual processes and incorporates it into the automated system. The system consists of two indexing/infeed stages, a 4-axis XYZ gantry system, an outfeed conveyor, and pneumatic vacuum/cylinder controls. TMD designed and built the machine, manufactured a custom control panel and HMI, and programmed the PLC/HMI.

With the introduction of automated elastic stapling, the operation was synchronized with the new process, resulting in a more controlled throughput. This approach also reduced the amount of manual processes required, such as manually moving fixture plates to different locations and manually applying a staple to the product.
 
The application is configurable to run up to 1,000 recipes for each fixture plate, selectable from the HMI. TMD provided dynamic controls and setup screens for easy program teaching and recipe creation. Each recipe can staple up to eight different locations on a fixture plate.
 
This new system reduced changeover time from 30 minutes to 5 minutes, allowing the client to run new products quickly. Additionally, by utilizing modular hardware and flexible programming, the machine can be fully customized for any elastic stapling task. It can even serve as a pick and place machine for simple material handling applications.
 
The client was highly satisfied, expressing admiration for not only the machine’s functionality but also its aesthetics — a reaction not commonly associated with manufacturing solutions. TMD adopts a meticulously detail-oriented approach to the design and manufacturing of custom applications. If you need such a solution on your manufacturing floor, TMD is your answer.