B&G Dot Peen Automation

With the new system, the operator could press a single button on the keyboard to activate all of the necessary operations. The automated system reduced setup time from around 15 seconds to around 4.5 seconds, improving efficiency by about 335% per piece and saving more than 1 hour of machine runtime per day.

• To automate the process, I selected a one-way pneumatic cylinder design for its ability to function in parallel with the machine's software and utilize the nearby air source as a form of energy. 

• The pneumatic system consisted of a 200 psi regulator to adjust the applied force, a three-way solenoid valve to control airflow, an adjustable hand valve to allow smooth extension of the cylinder stroke, and various NPT adapters. 

• One of the major challenges I faced was the implementation of an additional program in parallel to the machine's software because it could not be modified. 

• The machine was originally activated with a press of a key, so I utilized ESP32 and its keyboard detection library to incorporate the two programs into a single button. In addition, I employed a MOSFET to control the 24V solenoid valve & a position sensor to determine pen location and stroke retraction timing.

• All parts including the cylinder mount and base plate were manufactured from 303 Stainless Steel in stock via a manual mill or lathe. 

• The cylinder mount was secured to the rotary plate via a 3/8'' stud and flanged nut. Its center position, along with feature dimensions, was determined by measurements and machine drawings. When the cylinder pressed onto the parts, the thrust ball bearing at its end allowed the parts to spin freely with the rotary. 

• I also created additional mounts with different bearing sizes to accommodate the commonly stamped parts at B&G. Lastly, I tested each and collected data for their required air pressure.