Frames
Frames are designed specifically for the task and intended environment of the machine. Support and safety are calculated by considering the weight of the machinery and loads as well as the structural and material composition of the frame and supports. Frames are usually made of steel with a powder coated or one or two additive substrates depending on the environment to minimize corrosion. The frame base will be fixed or mobile. Fixed frames can be bolted to the floor to add greater stability.
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Other considerations for frame design include:
- Skeleton for parts mounting
- Access to control panels
- Security for moving parts
- Ease of cleaning walls
Fasteners
Fasteners are devices that connect components. Fasteners such as screws, nuts, bolts, washers, hinges and rivets form non-permanent joints. Your machine designer selects fasteners based on suitable form and function. Your concerns will include predictive and preventive maintenance, replacement of damaged fasteners, and optional equipment mounts. Checking for unnecessary frame vibration will reduce the occurrence of damaged and broken fasteners. If damage does occur, be sure to replace the fastener with a replacement that is rated correctly.
Tip - Predictive and preventive maintenance measures include:
- Monitoring of unwanted vibrations
- Visual inspection of relevant components
- Performance tests
- Avoiding stress elevation when installing new equipment or accessories (e.g. mounting kits or cable management system components)
Reduce fastener failures by:
- Ensuring fastener quality matches expected form and functional performance
- Avoiding over-tightening or under-tightening
Examples of fasteners:
Welded
Welded joints permanently join two or more metals. When properly designed and installed, welded joints provide stability by evenly distributing operating stresses on the frame, between components, and in combination with fasteners.
Welded Joints and Fasteners:
- Welded joints are stronger but lighter than fastened joints.
- Creating or repairing welded joints requires skilled labor or professional welding services.
Tip - Do not attempt to add or stabilize components or make repairs if you are unfamiliar with machine construction or the design of the components involved. Call a professional.
Electrical Panel Boxes and Enclosures
Electrical panel boxes and enclosures are structures that provide environmental control for machines, parts and operators. These enclosures are designed to organize and protect precision components from the movement of dust, dirt, oil and water. By meeting industry standards, the enclosures provide both operator safety and component protection.
Mechanical Devices
Next, we will look at mechanical parts. Through mechanical power distribution, mechanical parts can be fixed or welded directly to the frame to reduce instability and utilize additional support.
No matter how complex the automation technology, the fundamentals of one or more simple mechanical designs will be presented. In a typical automated machine, the mechanical components that are integrated with and work inside the electrical and electronic equipment are designed according to simple machine concepts.
Six simple machines:
- Levers are rigid rods that rotate and balance on a fulcrum (joint or hinge). The position of the fulcrum relative to the end of the lever will affect the mechanical advantage of the lever.
- Wheel axles are closely related to simple levers and today's gear systems. With this tool, the larger wheel circumference is locked to the smaller axle circumference so that the two rotate together with a pivot point at the center of the wheel. You have the mechanical advantage and the ability to accomplish a complete rotation of the axle.
- Tilting planes save energy by allowing objects to be raised or lowered with less force than physically lifting and lowering them. The mechanical advantage is determined by the angle of inclination. This is key when using automation to move items on a conveyor from one level to another.
- Wedges can separate two surfaces like a door stop, split two surfaces like an axe, or connect and secure like nails or screws. Mechanical advantage is realized by the slope of the length to the width.
- A pulley is an extension of a wheel axle. Objects can be moved up and down, left and right, by adding belts, cords, chains or ropes to the wheel. Mechanical advantage is achieved by adding additional pulleys (called pulley blocks). The extra pulleys and belts increase the amount of lifting without the need for additional physical labor.
- Screws are linear actions that convert rotational torque into adjustable height or depth - think screw-in lid or valve (faucet). The mechanical advantage of a screw depends on the circumference of the screw and the pitch of the threads. The smaller the pitch between the threads, the greater the mechanical advantage.
Mechanical or mechanized components provide a mechanical advantage by increasing the input force to get the job done with less energy. If the input force is less than the output force, you gain a mechanical advantage. Mechanical power transmission is designed to generate and control torque or determine the vectorial resolution of force.