FATEK Automation Corporation

With the rapid development of the stationery industry and increasing consumer demand for product refinement, correction tape as an essential tool for daily office and study continues to see growing market demand. Traditional correction tape production relies on manual or semi-automatic assembly, characterized by low efficiency and poor precision, making it difficult to meet mass production requirements with high consistency. Particularly in the assembly of key components - the main gear (drive gear) - manual operations frequently encounter issues like misalignment and gear jamming, directly affecting product smoothness and lifespan.

In this context, the fully automatic main gear assembly machine for correction tape has emerged. Specifically designed for the core transmission structure of correction tape, this equipment integrates high-precision positioning, automatic feeding, and press-fit detection functions to efficiently complete precise assembly between the main gear and tape core. Compared to traditional manual assembly, this machine not only increases production efficiency by 3-5 times but also ensures assembly accuracy within ±0.02mm, significantly reducing defect rates. Moreover, its modular design supports quick changeovers to accommodate different specifications of correction tape products, meeting diversified production needs.

Currently, the stationery manufacturing industry is accelerating its transition towards automation and intelligence. The adoption of main gear assembly machines not only addresses industry pain points but also provides crucial technological support for enterprises to reduce costs, improve efficiency, and enhance product competitiveness. Looking ahead, with deeper integration of intelligent manufacturing, this equipment is expected to become an indispensable core component in correction tape production lines.

This system adopts FATEK MS2C4-1616T PLC as the core control unit, achieving multi-station coordinated control through EtherCAT bus technology. Equipped with high-precision PPU motor-driven main gear station and inner reel station, coupled with industrial-grade vision guidance system, it achieves assembly accuracy of ±0.01mm. The vision system can capture spring position coordinates in real-time, guiding the robotic arm to complete precise material handling with automatic compensation function to effectively accommodate material dimensional variations.

The rotary table control system employs servo drive technology to achieve high-speed precision indexing at 0.5 seconds per station. After completing operations at each station, the system automatically triggers table rotation while the unloading station simultaneously removes finished products, forming an efficient closed-loop production process. The FATEK C2070NA-GF touchscreen provides an intuitive HMI interface supporting recipe management, parameter setting and real-time monitoring, enabling operators to quickly switch between different product models.

The system integrates comprehensive quality inspection functions to monitor critical parameters during assembly in real-time. In case of abnormalities, it automatically alarms and stops to prevent defective products. Production data is automatically collected and stored, providing enterprises with key performance indicators including production efficiency and yield rate. All critical components have passed 2 million cycles endurance testing to ensure equipment stability during long-term continuous operation.

By perfectly integrating precision mechanics, intelligent vision and advanced motion control, this control system achieves fully automated production of correction tape main gear assembly. Compared with traditional manual assembly methods, it improves production efficiency by over 4 times while reducing defect rate below 0.1%, providing stationery manufacturers with an efficient and reliable intelligent solution.

► Enhanced Assembly Efficiency
Traditional manual assembly methods are inefficient and inconsistent. This equipment adopts a fully automated control system to achieve high-speed automation throughout the entire process from main gear feeding, spring positioning to inner reel assembly, reaching an assembly speed of 20 units/minute, significantly improving production efficiency.

► High-Precision Assembly
Utilizing precision PPU motor drive and vision positioning system, the equipment achieves assembly accuracy of ±0.2mm, ensuring perfect meshing between main gear and tape core while avoiding common issues like misalignment and gear jamming in traditional assembly.

► Intelligent Quality Control
Equipped with vision inspection system for real-time monitoring of each assembly step. Automatic alarm and shutdown in case of abnormalities effectively controls defective products, increasing yield rate to over 99.9%.

► Flexible Production
Modular design enables quick changeover to take-up reel assembly mode by simply replacing molds, achieving multi-purpose use of a single machine and significantly improving equipment utilization.

► Intelligent Maintenance Management
The system features remote IoT capability, supporting network-based remote monitoring and maintenance through touchscreen and M-PLC, greatly reducing equipment maintenance costs and downtime.

► Complex Component Assembly Optimization
For challenging spring assembly, innovative soft-vibration dispersion + vision positioning technology precisely acquires gripping coordinates, achieving over 98% success rate in robotic arm grasping, effectively solving micro-component assembly difficulties.