1. Contactless Torque Transmission via Magnetic Coupling
To solve the vibration interference issue, we implemented a contactless magnetic coupling between the servo motor and the tensioner unit
- Vibration Isolation: Because there is no physical contact between the drive and the pulley, the magnetic field transmits torque while effectively blocking all high-frequency motor noise and mechanical vibrations.
- Automatic Engagement: The system automatically couples and uncouples each unit in the cycle. We integrated Tsubaki end cushions and dampers to absorb the shock of these rapid mechanical movements, ensuring the longevity of the coupling components.
2. High-Precision Data Acquisition (DAQ) & Control
The “brain” of the machine is built on a multi-layered industrial architecture:
- National Instruments (NI) DAQ: Used for high-speed vibration signal processing and FFT (Fast Fourier Transform) analysis to identify specific noise patterns related to bearing race damage or ball defects.
- Advantech Industrial PC: A ruggedized industrial computer manages the heavy data processing and storage requirements for the production line.
- Siemens HMI & PLC: A user-friendly Siemens Human-Machine Interface (HMI) allows operators to monitor real-time “Acceptance Time Series” graphs and adjust quality thresholds for different pulley sizes.
3. Advanced Pneumatics & Versatility
The machine is built for versatility, allowing for rapid re-tooling to accommodate various tensioner pulley geometries.
- SMC & Festo Pneumatics: The motion system utilizes a premium suite of pneumatic components, including single and double-acting cylinders, 5/2 and 5/3 way valves, and high-efficiency FRL (Filter, Regulator, Lubricator) units.
- Modular Design: The automation sequence is designed to be “size-agnostic,” adjusting its grip and stroke to fit different diameters of tensioner units as production requirements shift.
