FIELD OF INVENTION
This invention relates to an electro-pneumatically operated assembly machine for
assembling aluminium extrusions for control panel frame and a method for the same.
More particularly, the invention relates to a semi-automatic assembly machine for
assembling aluminium extrusions and corner blocks to form a square of frames of
control panels. These frames serve as the top and bottom component of the empty
cubicle which is made after assembling the long extrusions over these square frames.
BACKGROUND OF THE INVENTION
Control panels are manufactured in the form of large cubicles inside which various
electronic components are mounted and wired to perform logical functions for various
control applications in power stations. Basic skeleton structure of the cabinets is made
by assembling extruded aluminium profiles, cast aluminium corner blocks and socket
headed screws. The final size of each structure has to be 750mm x 750mm x 2230mm
height.
As the dimension of the size is critical workmen had to assemble and fasten the
extrusions by measuring many times in the process, with conventional measuring tapes
to keep and control the dimensions of the frame.

Moreover the assembly was carried out in two stages to simplify the manual process.
With all the cautions taken there was an offset to an extent of 15 mm in flatness in the
final assembly.
To overcome the difficulties the electro-pneumatic assembly machine has been
invented. The newly developed incorporates thirteen numbers of double acting
pneumatic cylinders, connected to actuate logically to position and clamp the extrusions
and corner blocks to maintain dimension and flatness till the screws are fastened to
hold them.
OBJECTS OF THE INVENTION
Therefore it is an object of the invention to propose an assembly machine for
assembling aluminium extrusions and corner blocks to form a square frame of empty
cubicle which can be used to complete the operation in a short time by using a single
setting instead of doing in three stages in the earlier method.
Another object of the invention is to propose an assembly machine for assembling
aluminium extrusions and corner blocks to form a square frame of empty cubicle which
is capable of an effortless assembly without any manual effort using pneumatic power.

Yet another object of the invention is to propose an assembly machine for assembling
aluminium extrusions and corner blocks to form a square frame of empty cubicle which
eliminates the manual measurements made too often during the earlier assembly
process to control the dimensions of the frame.
A further object of the invention is to propose an assembly machine for assembling
aluminium extrusions and corner blocks to form a square frame of empty cubicle which
is capable of assembling frames with complete flatness.
SUMMARY OF THE INVENTION
Accordingly, a hydro-pneumatically operated assembly machine (M) for assembling the
frames has been designed, developed and implemented in the panel assembly shop
which can be used with ease even by unskilled operators effortlessly. The machine (M)
is free from noise and also compact in size.
The machine (M) has been designed with simple pneumatic principle using thirteen
numbers of double acting pneumatic actuators. The machine has been provided with
easy-to operate electric switches that can be operated to actuate the pneumatic system
for clamping and uriclamping.

Consistently this machine (M) can produce the assembly keeping the accuracy in
dimension and flatness.
The machine (M) has been economically designed for operator's comfort and operating
convenience.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig.1 - shows the Line diagram of the full machine
Fig.2 - shows the Line diagram of the assembled frame.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE
INVENTION
According to this invention a new assembly machine (M) and a method has been
provided to assemble the aluminium extrusions and corner blocks without any manual
effort using pneumatic power.
A process that needs four numbers of aluminium profile extrusions (11) and four
numbers of corner blocks (12) to be assembled using sixteen numbers of socket headed
screws (13) as shown in Fig.2 was so far done in three stages manually. This was
taking more time due to elongated assembly method and due to manual measurement

to control the dimensions. Moreover the final component was having deviation in
flatness that was causing further more errors in the subsequent assembly.
To eliminate the deficiencies in the process and to improve the cycle time and
productivity a new machine (M) was invented and implemented in the shop for regular
use.
The new machine (M) is incorporated with a set of pneumatic cylinders (7, 8, 10 and
the other below 3) for locating and firmly holding the components while fastening the
screws.
Assembly is performed in a single setting and thereby the cycle time has been reduced
substantially.
Operator has to place the components and operate the switches (9) for clamping the
parts while the dimensions are set automatically. Screws (13) are assembled by using
power operated impact wrenches. Assembled component is removed easily after
unclamping by operating the switches.
Further, as there was no compact and simplified equipment available commercially for
such an operation it was decided to design and develop the machine internally.

Different cylinders have been provided to locate, hold and clamp the extrusions so as to
maintain accuracy and flatness. Actuation is done by simple electrical switches. The
various parts of the machine as shown in Fig.l are briefly explained below:
MACHINE FRAME
The frame (1) has been designed economically to place and hold the extrusions at a
convenient height for operation. The frame (1) has been constructed with steel tubes
for stability and strength. Also the frame provided support for top plate (2), pneumatics
and electrical components.
LOCATING PINS
Four locating pins (3) are provided to hold the corner blocks (12) in correct position.
These pins are capable to slide up and down through the four pneumatic cylinders (7)
actuated by a switch.
SIDE CLAMPS
There are three sets of clamps to hold the extrusions in position. One set holds from
inside to outside (4) and another from outside to inside (5). The third set holds it form
top to bottom (6). They are actuated by four peripheral cylinders (7) and one large
central cylinder (8). These are actuated simultaneously through a single switch.

LINEAR ROTARY CLAMP
Clamping the assembly from top against the base plate (2) is done using four numbers
of rotary linear actuating cylinders (10) operated by the switch meant for the side
clamps. These cylinders are capable of swinging in and out and also moving up and
down simultaneously during clamping and unclamping.
ASSEMBLING THE SCREWS
As shown in fig.2, totally four numbers of corner blocks and four extrusions are
fastened using sixteen numbers of socket headed screws tightened by a pneumatic
impact wrench for fast assembly.
After the assembly is complete the job is removed easily after actuating the switches in
reverse.
BENEFIT ACHIEVED
Installation of the electro-pneumatic extrusion assembly machine (M) and implementing
the new method of the invention in the assembly shops gives the following benefits:
• Minimization of assembly time due to single stage assembly and elimination of
frequent manual measurement.
• Quality improvement due to better dimensional control
• Improved the overall cycle time in assembly process of the panels.
• The total cost of development of the new machine is very economical.

WE CLAIM
1. An electro-pneumatically operated assembly machine (M) for assembling
aluminium extrusions for control panel frame comprising:
a frame (1) for holding the extrusions (11) and for providing support to top plate
(2), pneumatics and electrical components;
a plurality of locating pins (3) for holding the corner blocks (12) in correct
position;
a plurality of clamps (4,5,6) for clamping the extrusion (11);
a plurality of peripheral cylinders (7) and a large cylinder (8) for actuating the
inside and outside clamps (4,5);
a plurality of rotary linear actuating cylinders (10) for clamping the assembly
from top (6) against base plate (2);
characterized in that the assembly machine (M) incorporates a plurality of double
acting pneumatic cylinders connected to actuate logically to position and clamp
the extrusions and corner blocks for maintaining dimension and flatness till the
screws are fastened to hold them.
2. The assembly machine (M) as claimed in claim 1, wherein the machine (M) is
provided with nine numbers of double acting pneumatic cylinders (7,8).

3. The assembly machine (M) as claimed in claim 1, wherein the machine (M) is
provided with thirteen numbers of double acting pneumatic actuators (7, 8, 10
and below 3).
4. The assembly machine (M) as claimed in claim 1, wherein the machine (M) is
provided with three sets of clamps (4,5,6) for holding the extrusions in position.
5. The assembly machine (M) as claimed in claim 1, wherein the machine (M) is
provided with four locating pins (3) which are capable of sliding up and down
through four pneumatic cylinders below it.
6. A method to assemble aluminium extrusions for control panel frame in an
electro-pneumatically operated assembly machine (M) comprising,
holding the aluminium profiled extrusions (11) on the assembly machine (M);
holding the corner blocks (12) with locating pins (3) in correct position;
clamping the extrusions (11) with a plurality of clamps to clamp the said
extrusions from inside to outside, from outside to inside; and
clamping the assembly from top against the base plate (2); characterised in that,
a plurality of double acting pneumatic cylinders is connected to actuate logically
to position and clamp the extrusions and corner blocks to maintain dimensions

and flatness till the assembly is fastened by screws tightened by pneumatic
impact wrench.
7. A method as claimed in claim 6, wherein four numbers of corner blocks and four
extrusions are fastened by sixteen numbers of socket headed screws.
8. A method as claimed in claim 6 and 7, wherein the switches are actuated in
reverse to remove the assembly after completion of the job.

An electro-pneumatically operated assembly machine (M) for assembling aluminium
extrusions for control panel fame consists of a frame (1) that holds the aluminium
extrusions (11) and provides support to top plate (2), pneumatics and electrical
components. Four locating pins (3) hold the corner blocks (12) in correct position.
Three sets of clamps (4,5,6) clamp the extrusion (11). The machine (M) is equipped
with thirteen numbers of double acting pneumatic cylinders (7, 8, 10 and below 3).
Clamping the assembly from top against the base plate (2) is done using four numbers
of rotary linear actuating cylinders (10). Thirteen numbers of double acting pneumatic
cylinders (7,8, 10 and below 3) connected to actuate logically to position and clamp the
extrusions (11) and corner blocks (12) to maintain dimension and flatness till the
assembly is fastened by screws tightened by pneumatic impact wrench.