In the demanding field of catalytic converter production, where consistency matters, systems that exemplify reliability, adaptability and efficiency are the standard.
Grotnes rises to the industry’s stringent demands with our Weigh and Measure Canning Cells, devised for the assembly of catalytic converters. This integrated system includes an array of components, showcasing Grotnes’ advanced engineering capabilities, with each element integral to the production process.
Let’s take a closer look at the core of this system, where Grotnes’ commitment to precision materializes into a tangible reality.
The Servo Electric Sizer
Grotnes’ non-hydraulic, servo electric sizer is a breakthrough for operations involving multiple changeovers. Instead of the laborious task of switching individual tools, operators can now simply exchange a pre-staged cassette, inclusive of all necessary tooling. Additional cassettes are offered as required. Depending on the part configuration, cycle times can be as swift as 30 seconds per part.
Canning Cell: The Epicenter of Assembly
The Grotnes Canning Cell is the central hub where the magic happens, marrying the shell, substrates and mats that comprise the catalytic converter. Using Gap Bulk Density calculations, the system determines the appropriate sizing values. The Canning Cell is operated by a single operator who inputs components at the front and retrieves finished products via a conveyor. The system is adept at handling a variety of sizes, thanks to its flexible tooling and recipe changes.
Intelligent Integration: Poka Yoke and Traceability
Poka Yoke, the Japanese term for mistake-proofing, is integrated throughout the Canning Cell. This ensures errors are minimized and quality is upheld. Traceability begins immediately after the parts are fed into the cell, an essential standard for maintaining accountability.
Compact Yet Mighty Design
Grotnes’ Canning Cell is built with space efficiency in mind. Its compact design not only saves valuable floorspace, but it’s also engineered for high speeds and pinpoint accuracy. The system’s dual insertion cell feature enables the production of both double and single substrate catalytic converters.
Mat Weigh Station
The weigh station is the first checkpoint in the Canning Cell, where the mats are weighed with high precision. The operator positions the mat on a weigh scale equipped with an adapter table designed to handle a wide range of mat dimensions. The data is verified against the recipe and used to calculate the operator’s Gap Bulk Density specifications. Should a mat fail to meet the criteria, it is promptly removed from the station, signaled by a light alert.
Substrate Measuring Station: Laser Precision Scanning
Here, the substrate finds itself in a specially shaped nest, where it is rotated, and a laser sensor scans its perimeter at multiple heights. This data is critical for calculating Gap Bulk Density specifications. The station is equipped with barcode identification and printed text verification sensors to ensure correct directional loading of the substrate.
Wrap Stations: Aligning for Excellence
In these stations, the substrates are carefully loaded, aligned and prepared for wrapping. The system avoids any misalignments that could affect the quality of the final product. The wrapping station itself ensures an even wrap of the mat around the substrate.
Insertion and Adaptive Sizing
Post-wrapping, the substrates are pushed into the shell through a funnel that pre-compresses the mat. The adaptive sizing table then sizes the stuffed shell to meet the exacting Gap Bulk Density requirements; this is achieved using a moving sizer head equipped with a cassette system for rapid tool exchanges, reducing changeover times dramatically.
End Sizing and Verification: The Final Check
The end sizer, if required, recalibrates the shell’s endzones, allowing for the seamless integration with other exhaust components. Next, the verification station employs laser measuring sensors to confirm the product meets specifications, and DMC codes are validated for readability and content. Any rejected parts are quickly identified and moved to a quarantine area.
Laser Marking and Robotics
Every assembly is laser-marked for identification, and Grotnes’ advanced robotics ensure each component is handled with care. The robots, equipped with part-specific end effectors, maneuver the components through the cell without causing any damage.
Accessibility and Adaptation
The HMI screens support both English and international languages, with part production recipes easily accessible to accommodate various part configurations. Additional features such as Oxygen Sensor Hole Detection and a handheld barcode scanner streamline the production process, making certain the right components are used for each product.
Partner with Grotnes for Your Next Project
Grotnes’ Weigh and Measure Canning Cell for catalytic converters epitomizes our company’s devotion to delivering systems tailored to meet manufacturing challenges. Grotnes is also a global leader in the design and production of canning cells for off-road and commercial vehicle exhaust after-treatment systems.
For potential customers seeking the optimal canning cell for automotive catalytic converters, Grotnes stands as a guiding force, ready to deliver solutions that advance the industry standard.
Connect with us today to learn more about our comprehensive line of metal forming machinery.