Brush Assembly Machine Automation
Outers ATK is a division of Federal Premium Ammunition, a manufacture of a variety of gun accessories and gun cleaning
products including brushes
for all popular rifle and pistol calibers and all shotgun gauges. ATK needed a turnkey automated
brush assembly machine to increase their brush production rate and improve quality control.
Project Scope: Brush assembly and testing
The gun cleaning brush is assembled from two Outers manufactured components. A threaded ferule is placed over a wire twist
formed brush. There are multiple ferrule and brush dimensions. Assembled brush and ferule combinations are dependant upon the
type and caliber of the brush being produced. The new assembly machine needed to be capable of assembling all brush types with
minimal product change set up.
Project Design: Turn Key Machine Design
Industrial Automation's brush assembly machine design incorporates a direct drive servo to index a 36" aluminum disc. The disc
is fitted with 10 nests. Nine automated assembly stations are mounted just outside the indexing disc circumference. The assembly
fixtures include pin and sleeve locators so they can be quickly removed for service and reinstalled. Wire wound brushes are
delivered pneumatically to index station 2. The indexer
moves the brush to successive assembly and testing stations and adds
another new brush to station 2 at each index. Successive stations place the ferule over the wire end of the brush and crimp it in
place. When the completed brush has passed all inspections, a peen printer inscribes the caliber of the brush on the ferule. The
last stage picks the completed brush and places it in a good or bad brush chute dependent upon earlier assembly test results. An
Allen Bradley Micrologix 1400 controls all machine devices. Ethernet is employed to connect to a touch screen and the indexer servo control.
Safety: Machine Safety
The machine is fully guarded with interlocked doors and a light curtain. The light curtain is employed at station 1 to allow manual brush
loading and to meet OSHA standards. In manual loading, the indexer starts when a new brush is placed at station 1 and the operator is clear
of the protected area. An emergency machine stop is initiated if the light curtain is entered or a door is opened during index or if an
associated assembly station is active.
Project Results: Efficiency, Quality, Productivity
The completed automated brush assembly machine greatly improved production rates and assures that every brush is inspected. Product changeovers
are quick and easy.