Automotive Industry - Case Study #2517

Application -
Assemble a family of Seat Hinges consisting of over two dozen individual Plates, Rivets, Pawls, Spacers and Clock Springs.

Challenge -
Application requires an assembly method to accomodate Low-Volume High Mix assembly requirements.

Solution -
Assemble product through the use of a three standard CNC Orbital Forming Assembly Dials. The three cells are capable of forming Rivets in multiple positions to any height desired by simply changing the program and Part Nest. The Operator manually loads parts into the Quick-Change part nest and initiates the cycle start button. Once indexed the components will be verified via an inspection station. The Rivets are then formed to the proper height via a Taumel Forming Head. Each of the Rivets height and location are programmable via the three axis servo controlled Head Stock.

Bottom Line -
Due to implementation of Standard CNC Forming Cells the customer minimized the amount of capital usually required for a custom cell and is able to change to a different part in less than five minutes providing flexibility to run smaller lot sizes and adjust to accommodate just it time requirements.

Electronics Industry - Case Study #2599

Application -
Weld, Drill, Mill and Tap a Metal Bracket for an Armature Assembly.

Challenge -
Project Specifications require an assembly method to accommodate a one Operator cell to process parts at a rate of 7 parts per minute.

Solution -
The first process consisted of a Banner Welding system, equipped with Optic Fiber to verify proper part placement into the fixture. Operator would place the two target parts into the fixture and initiate cycle start on the Banner Welder. Once initiated, the two parts are welded together. Next, the operator places the Weldment into an automatic indexing dial and initiates cycle. This second station inspects the Sub-Assembly to verify the proper components were welded. The third station mills the welded surface flat. The fourth station drill two holes simultaneously via twin Hypneumat spindles. The fifth station Drills an additional hole and Taps a hole via two hynuemat spindles. The six station automatically deburs the part; the seventh station removes the finished sub-assemblies and places them onto a Dorner conveyor system.

Bottom Line -
Due to implementation of the Hypneumat Spindles, Camco Indexer, Dorner conveyor, Banner Welder into and Automatic assembly line, the customer was able to reduce the amount of labor content required to produce a part and increase the consistency and quality of the part in the process.

Automotive Industry - Case Study # 2502

Application -
Automatically Weld two Body Support Panels together via Spot Welding.

Challenge -
Application requires welding of a 60” long structural panel utilized by a major automotive company. The size of the part presents a challenge at a rate of two Sub-Assemblies per
minute .

Solution -
Assemble product through the use of a 3 station Camco Indexer. The Operator loads the two panels onto Custom designed fixturing and initiates cycle. The fixturing is equipped with live rotating clamps to secure the part in position during the welding operation. The second station is equipped with a custom designed CNC positioning system. The custom system supports four Centerline Welding heads. The heads perform welds at four different programmed positions. Once complete, the part is indexed to a third position where the parts are again welded via a four Centerline Welders mounted onto a CNC controlled positioning table. Once the welds are complete, the part is lifted off the fixture and transferred in front of the operator for removal .

Bottom Line -
Due to the automatic assembly dial, operators are able to load parts while others are being welded. This allows the parts to be produced simultaneously so that throughput can be optimum.