This system supports: • Non-Lethal Weapon Production • Riot Control & Tactical Equipment • Military Training Simulations • Signal & Marker Devices Applicable Institutions: • Ordnance factories • Homeland security divisions • Private defense OEMs • Field-deployable production units
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1. Product Vision & Background The A3679 machine represents a paradigm shift in non-lethal munition manufacturing, marrying turnkey automation with inviolable safety standards. As global defense and security agencies increasingly rely on less-lethal counter-riot and training tools, production lines must guarantee both operator protection and batch-to-batch consistency. - Strategic Context: Urban peacekeeping, crowd control, and special forces operations demand devices—like stun grenades with intense flash/sound effects, and dye markers for suspect tracking—that are both effective and environmentally safe. - Engineering Mandate: Handling finely milled pyrotechnic powders requires dust-explosion mitigation, precise dosing, and zero-contact assembly. The A3679 responds by enveloping every fill, seal, and torque step in a flame-proof enclosure, so that no human hand enters a hazard zone. - Operational Footprint: Designed for defense OEMs, ordnance factories, and paramilitary depots, this compact 7.5 m × 4 m line slots neatly into existing plant layouts. Its modular stations can be reconfigured or expanded—supporting future product variants with minimal retrofit. - Sustainability & Compliance: Beyond ATEX and CE, Neometrix embeds digital traceability—every fill weight, torque reading, and batch code is logged for decades-long audit trails, ensuring compliance with MIL-STD protocols and national export controls. 2. What It Does – Functionally Defined At its core, the A3679 automates the complete life cycle of two distinct grenade types in a single-line solution: 2.1. Stun Grenade Assembly - Composition: A precisely weighed mix (~30 g) of aluminum powder, magnesium carbonate, and potassium perchlorate, calibrated to generate a 180 dB acoustic blast and >5 million cd/m2 flash. - Safety Layering: In-line inerting prevents static build-up; all transfer lines are grounded, and filling occurs under slight positive pressure to keep external oxygen at bay. 2.2. Dye Marker Grenade Assembly - Composition: 3–7 g of chlorate-lactose-dye mixture that releases opaque colored smoke on ignition—ideal for marking targets or perimeters. - Residue Control: A scavenging air-scrub station at discharge captures excess pigment, safeguarding downstream stations from cross-contamination. Universal Process Flow: - Raw Shell Feeding: Vibratory hoppers singulate bodies. - Precision Filling: Dual hoppers and swappable nozzles adapt automatically to each material’s flow properties. - Bonding & Sealing: Epoxy, shellac, and NC lacquer stations create multi-layer seals, each applied with micron-level volumetric pumps. - Mechanical Assembly: High-torque servo drivers and vision-guided arms place H-plates, caps, strikers, and springs with 0.1 Nm and 0.02 mm repeatability. - Labeling & Inspection: Tamper-proof QR labels are printed on demand; a vision system confirms code readability and placement accuracy. - Ejection & Sorting: Faulted units are automatically diverted to a reject bin, with root-cause flags logged. 3. Advanced Engineering & Process Walkthrough The A3679’s 17-station layout is driven by a single Mitsubishi PLC, but each station represents a miniaturized, self-contained factory: Station 1: Pre-Feed Inspection – Vision sensors check shell integrity; misshapen units are rejected before entering the line. Station 2: Air-Knife Cleaning – High-velocity air blades remove dust without mechanical contact. Stations 3 & 4: Fill Stations – Twin gravimetric loops with load cells automatically dose within ± 0.05 g. Stations 5 & 6: Adhesive & Coating – Heated reservoirs maintain viscosity; peristaltic pumps meter to 0.02 mL resolution. Stations 7 & 8: H-Plate Bonding & Torque – Tools ratchet to 2.5 Nm ± 0.1 Nm, auto-stop on mismatch. Station 9: Lacquer Cure Tunnel – Infrared lamps pre-cure NC lacquer in under 20 s. Stations 10 & 11: Secondary Fills – Gunpowder and silicone oil dosing use positive-displacement pumps. Stations 12 & 13: Cap & Striker Assembly – Dual-arm robots install components under machine-vision guidance. Station 14: Brush & Blow-Off – Rotating brushes and air jets finalize cleaning. Station 15: Label Wrap Station – Four-axis labeler contours to grenade geometry. Station 16: Final Torque Check – Secondary torque sensor verifies striker seating at 1.2 Nm ± 0.05 Nm. Station 17: Automated Unload – SCARA robot places finished units into trays or packaging. 4. Control & Automation Infrastructure - PLC Core: Mitsubishi iQ-F (FX5U) with motion modules and 1 ms I/O cycle. - HMI Interface: 7′′ capacitive multi-touch panel with recipe library, live dashboards, and hierarchical alarm management. - Communication & Security: Ethernet/IP, CC-Link IE, OPC-UA; VPN-ready with two-factor authentication. - Embedded Safety Logic: Dual-channel emergency stops, interlocks on all access points, overfill protection via load-cell cutoff. 5. Specifications: Performance Meets Precision
