Ceramic components production automated

A system that automates the five stages of manufacturing has increased production of high dielectric ceramic components for GPS aerial antennas by more than 50%.

Leading systems integration and testing specialist Mechatronic Solutions, has enabled Morgan Advanced Ceramics to increase production of its high dielectric ceramic components for GPS aerial antennas by more than 50%.

The increase has enabled the technical ceramics manufacturer to meet growing worldwide customer demand for the components, which have been designed to offer low energy loss, providing excellent dielectric resonator for microwave applications.

The challenge set by Morgan Advanced Ceramics' facility in Stourport, UK - where the antenna components are manufactured - was to provide a 24/7, 50-weeks-a-year system.

After consulting several automation and integration specialists the company chose to work with Mechatronic Solutions.

This decision was made as a result of Mechatronic Solutions' proven capability in high quality bespoke automation solutions and its strengths in timely delivery of economic, reliable and robust equipment and processes.

The system was designed to incorporate the five stages required for production of the parts: Component pressing; presentation and offloading to the kiln; cooling, orientation checking and automatic loading of components into grinding machinery; washing and drying of components before automatic handling to the banding machine and automated banding for validation and packaging.

Several innovative techniques - including soft handling of parts within the furnace to eliminate damage and the use of high-speed camera imaging in the grinding process - were also incorporated into the process to ensure the consistent, reliable high-speed operation required.

"It is about finding the right combination of robotics, pneumatics, high quality engineering and computer software," explains Richard Evans, managing director, Mechatronic Solutions.

"And then finding the best way to integrate it within the customer's existing equipment and processes." Paul Haddon, project manager, Morgan Advanced Ceramics confirms: "Mechatronic was able to develop an uncomplicated solution for a complicated manufacturing process." As a result of the new system Morgan Advanced Ceramics has been able to increase production in line with its requirements and has also been able to reduce operator input in potentially hazardous environments, creating a safer working environment for its staff.

Haddon concludes; "We have been producing the GPS aerial antenna components for more than three years and our reputation with our customer is built on fast, reliable, consistent production.

It is imperative to the business that we can grow in line with demand yet retain those competencies and this new manufacturing process enables us to do that." * About Mechatronic Solutions - Mechatronic Solutions is leading systems integration and testing specialist based in Birmingham, UK.

The company has built an excellent reputation for the design and manufacture of high quality bespoke manufacturing, assembly and test machinery.

Mechatronic provides automation solutions to a diverse range of industries and over the last 15 years we have helped over 260 customers with successful installations.

* About Morgan Advanced Ceramics - Morgan Advanced Ceramics (MAC) has a comprehensive range of ceramic materials, from which its products are manufactured.

Supplying to a variety of demanding markets, MAC has established an enviable reputation for providing value-added solutions through world-class research and development, innovative design and, perhaps most important of all, application engineering.

As a subsidiary of The Morgan Crucible Company, MAC forms part of the Morgan Technical Ceramics Group.

The Group includes Morgan Electro Ceramics and from manufacturing locations in North America, Europe and Asia, it supplies an extensive range of products, including ceramic components, braze alloys, ceramic/metal assemblies and engineered coatings.

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