Custom Designed Automated Vision Inspection and Data Logging System for the Automotive Manufacturing Industry

greencrest on March 27, 2022

An automotive Tier 1 manufacturing client approached MJ Engineering to design and install a quality system for the purpose of logging data and images from assemblies to provide product traceability. The system uses a 2D reader to read the unique serial identifier and then record the associated assembly data.

One part of the assembly process requires installing screws to specified torque requirements, the next stage is an automated vision based part inspection that checks to make sure the system is assembled correctly. Both the torque data and the vision image are logged to permanent files.

If the torque reading does not fall within tolerance or the vision inspection testing fails the part is not allowed to be packaged and an alarm will sound if an attempt is made to package failed parts.

Project Description

This automated Quality system reads and logs; 2D datamatrix codes, torque values and vision inspection pass/fail criteria.

Capabilities Applied/Processes

Station Design

  • Create custom application software to preform logic and logging functions
  • Create SolidWorks 3D Models of Station Concept
  • Vision and lighting application concept and testing

Installation
Start-Up
Operator and Maintenance training

Features/Benefits

Features
Utilizes SICK© Inspector camera and SICK© Lector 2D reader
A PRODFACE© Industrial PC / HMI is used for operator interface, data logging and logic control
Portable Cell
Provides visual and audible feedback on each part inspected.

Benefits
By utilizing this custom quality control station the customer was able to meet their customers’ quality control standards.
This system virtually eliminates the possibility of shipping incomplete and / or incorrectly assembled parts.
Easily modified to meet new product requirements.

More Info

Overall Cell Dimensions
Table top unit: 36″ High x 48″ Wide x 24″ Deep

Pattern Size Capabilities
1.5″ High x 4″ Wide

Tightest Tolerances
0.05 inch

Material Used
None

In Process Testing Performed
Samples of all models were provided for initial concept testing

Industry for Use
Automotive

Delivery Location
Ohio

Standards Met
Customer supplied quality requirements

Product Name
Automated Vision Inspection and Data Logging System

Engineering of Continuous Miner for the Coal Mining Industry

greencrest on March 27, 2022

MJ Engineering was approached by a coal mining company to engineer a new continuous miner. We were tasked with not only creating a miner that used the latest technology but also one that could be cost effective.

We began by designing the miner using Pro/ENGINEER software to create a 3D CAD model. Our design team also provided the client with a complete drawing package including a BOM and aided in selecting and procuring the OEM parts.

The continuous miner, which has steel with chromium carbide overlay in the conveying path, meets all MSHA and ATEX safety requirements. It is also capable of mining up to 14.5’ high coal and comes with a remote control pendant and the latest in motor control systems technology.

To find out more about our engineering and design service please contact MJ Engineering. For more information about this specific project please see below for details.

Project Description

MJ Engineering Engineered a new Continuous Miner that could compete in the market using the latest technology while maintaining cost effectiveness.

Capabilities Applied/Processes

  • Design/Engineering
  • Designed Miner Using 3D CAD Modeling within Pro/Engineer
  • Provided Complete Drawing Package Including BOM
  • Lead Engineering in Design Group
  • Aided in Selecting & Procuring OEM Parts
  • Finite Element Analysis (FEA)
  • Performed FEA on Major Components
Process Requirements

  • Meet MSHA & ATEX Safety Requirements
  • Mine in a 9’ to 14.5’ High Seam
  • Latest Technology in Motor Control Systems

More Info

Overall Dimensions
Length: 40’
Width: 12’

Material Used
Steel Plate & Bar: T1, A36, AR 400, A572 Gr. 50 and Chromium Carbide Overlay.
Steel Tubing: A500 Gr. B

Industry for Use
Coal Mining

Standards Met
Customer supplied specifications
Mining Safety & Health Administration (MSHA)
ATEX

Product Name
Engineering of Continuous Miner

Finite Element Analysis of Shuttle Car Canopy for the Mining Industry

greencrest on March 27, 2022

MJ Engineering was approached by a client to analyze the canopy design of a new mine shuttle car. The West Virginia-based customer asked us to verify that its shuttle car conformed to all current mining standards.

Using finite element analysis (FEA) we tested the shuttle car’s canopy and provided the needed engineering design to guarantee that the canopy conformed to MSHA standards and load ratings. Because of MJ Engineering’s outstanding design team, our customer was able to avoid the difficulties and cost of purchasing and maintaining FEA software and having to keep a professional engineer on staff. As always MJ Engineering also provided our client independent design advice and an industry leading level of customer support.

If you have any questions about this project or any of our other services please contact MJ Engineering or check out the details listed below.

Project Description

MJ Engineering Analyzed the Canopy Design of a new mine shuttle car, verifying that it conforms to mining standards.

Capabilities Applied/Processes

Performed Finite Element Analysis (FEA) in SolidWorks’ Simulation

  • Analyzed Operators Canopy

Design/Engineering

  • Provide Engineering Design to Bring Canopy into MSHA Standards
  • P.E. Certification of Canopy

Features/Benefits

Process Requirements
Must Conform to MSHA Standards

Benefits

  • Customer has no need to purchase and maintain a copy of FEA software
  • Customer receives independent design advice & review
  • Customer does not need professional engineer on staff

More Info

Industry for Use
Mining

Delivery Location
West Virginia

Standards Met
Mining Safety & Health Administration (MSHA)

Product Name
Finite Element Analysis of Mine Shuttle Car Canopy

Backlight Conveyor

greencrest on March 27, 2022

Conveyor Width (in.) Conveyor Load (lbs.) Backlight Width (in.)
5 80 3.5
6 90 4.5
8 100 6.5
10 120 8.5
12 120 10.5
18 120 16.5
21 120 19.5

Project Description

The MJ Engineering Backlight Conveyor is a modified conveyor that possesses ULTRA-BRIGHT backlight capabilities which could be utilized to improve product inspection and manual assembly operations.

Capabilities Applied/Processes

Extruded Aluminum Frame

Sizing

Benefits

Intensity

  • Ultra-High intensity
  • Reduced inspection (image acquisition) time
  • Improved image quality

Reliability and Efficiency

  • Increased production rates
  • Easy access for maintenance
  • Quick and easy cleaning

Portable

  • Light weight
  • Store additional fixtures

More Info

Options

  • LLegs/Feet
  • Drive: AC, DC, Servo
  • Conveyor speed
  • Belt material (limited options)

Oral Syringe Filling Machine Cuts Time and Waste

greencrest on March 27, 2022

A client in the medical industry needed a faster, more reliable method of filling oral syringes with liquid medications. Having human operators fill syringes one at a time was not efficient. That system led to inconsistencies between operators, and waste, due to air bubbles, causing inexact measurements of medicine.

To solve the client’s problem, MJ Engineering developed a machine that can automatically fill up to four syringes at once with the exact amount of fluid desired every time. It reduces or eliminates air bubbles and is faster and more precise than a person or machine filling one syringe at a time. Additionally, it is less complicated and expensive than a fully-automated, high-speed line of equipment.

With MJ Engineering’s machine, an operator can select a pre-programmed “recipe,” which contains information about the size of the syringe and other settings. When ready, the operator loads the bottles and syringes into the machine and presses a foot switch to start the automatic filling process.

MJ Engineering’s oral syringe filling machine can fill up to 400 syringes per hour, doubling the number filled by the client’s most experienced human operator.

In addition to its fast, easy, hands-free operation, the oral syringe filling machine developed by MJ Engineering uses safety light curtains and other methods to protect the operator, and it is made of stainless steel and aluminum for easy cleaning.

To learn more about our engineering and design services, please contact MJ Engineering. For more details about this specific project, refer to the following information.

Project Description

MJ Engineering designed and developed an oral syringe filling machine that saves time and reduces waste for a client in the medical industry.

Capabilities Applied/Processes

  • Designed to fill syringes with liquids of varying viscosities at a volume as low as 0.1 mL
  • Equipped with four, customizable grippers that can handle variable syringe sizes (currently available: 0.5 mL, 1 mL, 3 mL, 6 mL, 12 mL, and 20 mL)
  • Holds up to 999 programmable recipes
  • Adjusts to fit bottles from 3-in. to 7.5-in. in height
  • Fills up to four syringes at once
  • Flips bottle and syringe for filling, eliminating the need for a valve
  • Primes the syringe to reduce or eliminate air bubbles
  • Uses a servo motor with an encoder that goes to a repeatable position for the exact same fill level every time
  • Documentation provided in hardcopy and electronically
  • Training provided for operation and maintenance

Features/Benefits

  • Foot switch/handsfree operation
  • Stainless steel and aluminum parts/easy wipe down
  • Safety light curtains and power lockouts/operator safety
  • Four, customizable grippers/increased speed of operation

More Info

Overall Dimensions
Width: 48 in.
Height: 76 in.
Depth: 46 in.

Electrical Specifications
120 VAC, 1 Phase, 60 Hz, @ 30 Amps

Material Used
Stainless steel and aluminum

Industry for Use
Medical

Delivery Location
Ohio

Product Name
Oral Syringe Filling Machine