SMED
The
SMED (Single Minute Exchange of Die) prototype was developed to illustrate a
method for reducing changeover time on production lines for currently manually
adjusted equipment. The prototype is a
box folding machine fitted with linear actuators or electronic rams which
transmit position information to a microcontroller, which in turn controls
their motion.
The
prototype will be used to illustrate the reduction in time and manpower for
changeovers, and hopefully encourage relevant companies to have frequently
adjusted equipment converted to free up engineers for other work and improve
output. The outcomes would include a
reduced downtime and additional flexibility in batch production.
The
box folding machine was constructed with linear actuators instead of a
nut-and-bolt method of changing settings.
Linear actuators work by a motor attached to a spindle which moves a ram
forwards or backwards depending on the polarity. A resistor is incorporated which changes in resistance as the ram
moves out, and by putting a voltage across this it is possible to determine the
position to a high degree of accuracy.
The simplest method of control we decided would be to use a programmable
microcontroller, and a type of circuit known as an H-bridge which provides
power to the motors based on logical input signals. These are common circuits and are produced in microchip
form. I drew up a circuit diagram of
the motor controller circuit including a few other components to ensure correct
operation. The prototype incorporates
four actuators, so I produced a plan and mounted four motor control circuits on
stripboard (a plastic grid with holes for components to be mounted easily, and
parallel strips of copper to connect individual lines of holes). We used a transformer to convert mains
electricity to 24v DC. The
microcontroller provides logic signals of 5v to trigger the motor controller circuits
which then channel 24v to the actuators.
The microcontroller contains a program which accepts controls from a
computer via a serial cable and moves all four actuators the correct distance
simultaneously. Fine tuning is
accomplished by 'nudge' functions which move individual actuators forward or
backward by a fraction of a millimetre.
The
main challenge was the current limit of the H-bridge chips. Each chip includes two H-bridges, and so, in
theory, can control two motors, but the actuators draw a higher current than
the H-bridge chips can cope with, so the controller circuits had to be
paralleled up. By controlling only one
actuator from each chip, the current rating of the chips is doubled. Unfortunately, even this was inadequate for
when the motors were drawing full power, and two chips burnt out during initial
testing. The testing also showed that
the actuators were too fast for accurate positioning by the program. Both problems were overcome by rerouting the
power supply to the motor control circuits through resistors which would both
reduce the current through the chips and slow the actuators down. Fuses were also added to be doubly sure the
circuit would be protected in the event of a short.
This
prototype has been developed for display at relevant conferences. It will be available for many companies to
see, and, if the idea is taken on by companies with a lot of production line
work, it could save a lot of money. In
the food industry especially, changeover time is becoming a larger proportion
of downtime as batch sizes become smaller and flexibility is key to
success. The simplicity of the design
from the operator's point of view means it can be employed by people with minimal
training and at lower risk than previously.
Batch sizes currently mean that equipment is used at one setting for an
hour and then brought out of action for 10 minutes to prepare for the next
batch. Compared to this our prototype
will reduce changeover time by at least 90% with proportional cost and manpower
savings as well as added flexibility.
The nature of the work has
necessitated a better understanding of electronics and computer
programming. It has improved my skills
in planning as well as electrical circuit and system assembly.
The
rig was designed and built to illustrate the rapid changeover concept some
years ago, but the control method was more complex. Our prototype provides an easy-to-use, desk-mounted demonstration
piece.