ABB robot delivers the quality finish for Tenma

Citation

(1998), "ABB robot delivers the quality finish for Tenma", Industrial Robot, Vol. 25 No. 2. https://doi.org/10.1108/ir.1998.04925baf.006

ABB robot delivers the quality finish for Tenma

ABB robot delivers the quality finish for Tenma

Speed and precision is the by-word of Tenma (UK) Limited, a class leading injection moulding company set up by its Japanese parent in Scotland. The motto applies to Tenma's injection mouldings but it is also an apt description of the robot finish spraying system supplied by ABB Flexible Automation and now in operation at the Cumbernauld plant just outside Glasgow.

When Tenma's UK operation was established in 1988, it had one key purpose, "to bring Japanese standards of expertise and commitment to the European injection moulding markets". Nine years on it has proved its ability to match the standards of its five Japanese factories. Initially the plant was dedicated to moulding for the teletonics industry supplying local TV manufacturers such as JVC and Mitsubishi. Today, it also manufactures components for Canon printers, Nokia remote control units, as well as producing its own brand of house ware, a strong product line in Japan, and a variety of engineering thermoplastic parts.

But Tenma is more than an injection moulder. It assembles complete units using adhesive and ultrasonic welding technologies and finish paints them to the highest quality standards. Initially it used manual and automatic reciprocator spraying for finishing, but in its quest for continual improvement, it looked for ways to reduce manufacturing costs and save materials while further improving finish quality. Robots were seen as an answer to these problems.

Gerry Mooney, paint assembly manager, comments:

"We considered other forms of automation, including electrostatic bells, but none could match the finish quality and transfer efficiency of robots. They are able to precisely lay down paint over the complex contours of a TV cabinet with minimal amounts of overspray. This not only saves on materials but also reduces the plant's emissions to the atmosphere, which we are continually striving to improve as part of our on-going relationship with SEPA (Scottish Environmental Protection Agency)."

The system installed at Cumbernauld by ABB incorporates two shuttle tables, an ABB TR 5000 electric drive painting robot and delivery system for the water borne paint. After moulding, the cabinets have a number of items assembled before being transported to the spray booth on carriers suspended from an overhead conveyor. The operator transfers the cabinets from the carriers onto workholders on each of the shuttle tables in turn. The robot applies the paint to all the outer areas of the cabinet's sides, top and bottom and front. The operator then returns it to a vacant carrier for continued transport to a flash-off zone and gas-fired curing oven.

The robot is equipped with a special system permitting us to alter paint flow, air pressure and fan settings during the painting cycle. The different "brush" settings enable us to improve the quality of finish consistency and keep paint wastage to a bare minimum.

Currently the robot system is operating on a single shift basis, painting cabinets for JVC in one of four different materials. However, a second shift is planned for painting Mitsubishi cabinets when their models are switched to water borne materials next year. This further demonstrates the flexibility provided by the ABB robot painting system.

For further information contact Jane Attwood, ABB Flexible Automation Limited, Auriga House, Precedent Drive, Rooksley, Milton Keynes MK13 8PQ. Tel: 01908 350300; Fax: 01908 350301.