June 12, 2017

Ignition Charge and Powder Loader

Machine No. 5789

Ignition Charge Loader

Magazine feeds igniter headers through an inline track to a dead track where they are picked and placed into a nest on a 12 position indexed dial plate. Headers are then checked for proper orientation and loaded with a pre-measured shot of powder. After loading, the powder is consolidated with a consolidation press and the powder height is checked. Rejected parts are offloaded through a tube to a reject part bin. Good parts are offloaded into a track system for conveyance down the production line.

MACHINE CONTROL – A solid state programmable controller operates the sequence with an easily accessible control panel including Main Power, Emergency Stop, Manual, Automatic, and Individual Operations controls.

CYCLE RATE – Estimated cycle rate, 25 to 30 per minute.

CONSTRUCTION – Heavy duty welded and powder coated tubular frame with adjustable levelers. Materials and finishes used are appropriate for the work environment. This machine is designed to allow the operator full visual contact with all components being processed and easy access for routine maintenance.

SAFETY – Meets OSHA Safety Standards. Safety sensitive areas of this machine are enclosed and accessed through interlocked doors which stop the machine when opened. Emergency Stop Controls are provided which stop the machine when activated.

Machine No. 6407

Ignition Charge and Powder Loader

This machine is used to load powder into the Igniter Can and insert and press an Igniter Header into the can. Cans are bowl fed from a 10” CCW feeder bowl through an inline feeder track to a dead track where they are picked up by a 4 Station vacuum head oscillating turret and advanced through a can weigh station and an idle station and placed into a nest on a 16 station cam driven index table. The pre-weighed can is indexed to the powder load station where a spoon is automatically moved into a protective barricade where a feeder bowl volumatically fills it with powder.  It is scraped off level while exiting the barricade and the powder load is dumped through a funnel into the can. The powder bowl barricade is built to withstand an explosion of many times as much powder as is allowed in the bowl and direct the blast up through the roof. The powder filled can is vibrated to level the powder and picked up by a dual head oscillating parts placer and placed on a load cell weigh station. Simultaneously a weighed powder filled can from the previous cycle is placed into the index table nest. Bridged headers from the bridgewire welder are track fed with the pins down thru the production line track system to a dead track where they are picked up by a dual head oscillating parts placer and flipped 180 degrees and placed into the proper weight powder filled cans. The headers are then seated to a desired height in a press station. Good parts are offloaded into an inline feeder track for further conveyance down the production line track system. Reject parts are offloaded through a tube through the table top into a reject part bin.


CONTROLS – The control system uses an Allen Bradley PLC5  running a ladder logic program to control the real time sequencing of the machine.  Operator interface, data logging and any other interface to high level devices is provided by a custom Microsoft Visual Basic program running on an Intel powered PC using Windows NT Workstation 4.0 as the operating system.  The control system provides the following standard features as well as many others:
· Machine Status display and messages for any machine fault stops.
· Storing, loading and editing operational parameters, by customer part number.
· Operational Mode selection.
· Production data accumulation by Year, Week, Day, Hour and Lot.
· Manual control of each output and status monitoring for each input for every station.