Breathing Filter Assembly and Testing Line

The world’s leading manufacturer of filtration, separations and purification products approached APL to design and develop a fully automated equipment to aid in the assembly and test of medical breathing filter. The system includes a standalone filter assembly machine, conveyor and cooling tower and a filter test machine.

Breathing Filter Assembly and Testing Line

Key features & benefits

  • Custom pad printing machine with rotary indexing table
  • High speed and user-friendly
  • High precision and repeatability
  • High productivity
  • Low maintenance

All of these benefits deliver a short payback period and impressive return on investment.

The Solution

Assembly Machine

Breath Filter Assembly Machine Vision SystemStation 1 – Machine side mouldings hopper & bowl fed to conveyor, orientated, stream split and loaded to the rotary table by pick and place.
Station 2 – Patient side mouldings hopper & bow fed to conveyor, orientated, stream split and loaded to the rotary table by pick and place. Cap clips checked.
Station 3 – Filter pack automatically loaded (method to be agreed when pleater spec defined) to buffer conveyor and pick and placed to rotary table. Pack width checked, for orientation.
Station 4 – Hot melt adhesive applied to cap with hot melt equipment and robot.
Station 5 – Hot melt & filter pack inspection.
Station 6 – Housings inverted and placed to caps & components tamped together.
Station 7 – Filter assemblies checked for final assembly height & unloaded to a single buffer conveyor.
Station 8 – Reject components will be unloaded to a reject container.
Station 98 – Consists of an 8 stop rotary to transfer product between stations. The table will have nests tooled to suit the machine side moulding & patient side moulding

Cooling tower

Station 9 – With buffer conveyor to transfer filter assemblies to the cooling tower. Cooling tower with filter lift and lower units to store and cool the filters. Conveyor to transfer filter assemblies between the cooling tower and filter 6test m/c.

Test Machine

Station 11 – Complete filter assemblies loaded to the test machine rotary table.
Station 12 – Complete filter assemblies are leak tested.
Station 13 – Reject leak test components unloaded to reject bin.
Station 14 – PAO test nest positions 3&4.
Station 15 – PAO test nest positions 1&2.
Station 16 – Apply inkjet mark and inspect.
Station 17 – Salt test unload rejects.
Station 18 – Complete filter assemblies unloaded to bagging machine.
Station 98 – Consists of an 8 stop rotary table with nests tooled to suit patient side mouldings in 4 positioning to transfer product between stations.

APL Skills

Machine building and integration, machine and process control, Rotary indexing tables, Assembly and testing, Feeding and handling, Pick and place, Project management

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Breathing Filter Assembly and Testing Line

Breathing Filter Assembly and Testing Line

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