Electronics Industry - Case Study #2342

Application -
Automatic Assembly of a Flux Tube to Electronic Coil Assembly.

Challenge -
Automatically Assemble Two Flux Tubes to Two Coils at the same time while monitoring the Force utilized and Distance that the Press Head traveled. Customer provided all designs and prints. Baker worked with internal design group to build and debug system.

Solution -
Assemble product through the use of Semi-Automatic Bosch Power and Free Conveyor System. Operator manually places two Flux Tubes and Two Electronic Coil Assemblies onto a Pallet and initiates cycle start. Parts travel from Station to Station via the Power and Free Conveyor System. Once the Pallet reaches the first station, a test will be performed to sense the presence of all the parts and verify the Coil Terminals are within manufacturing tolerance. The Assembly Station consists of multiple Press Stations the Pick and Press the Flux Tube in Place. The Force and Distance of the Press Rams will be monitored throughout the process to verify the correct assembly parameters. The final station consists of an automatic offload system, which will also separate the good parts from rejected parts.

Bottom Line -
Due to the Automatic Assembly and On the Fly Force and Distance measurement, an Operator is able to run both this System and nearby Coil Winding equipment at the same time.

Electronics Industry - Case Study #2587

Application -
High Volume Assembly of Electronic Torque Sensors.

Challenge -
Design and build a custom assembly system to automatically perform several assemblies and test operations on an Electronic Torque Sensor.

Solution -
Work intimately with customers launch team to develop an approach, which accommodated all the teams’ goals. The system begins with a multiple IAI servo controlled gantry systems, which transfers Trays of Torques Sensors to a Cure oven. Once cured, the parts are transferred through plasma cleaning system, then to a wire bonder and stacking mechanism, which stores several trays in a Cage for manual transportation onto the last half of the Assembly Line. Next, the Cage is placed into the Destacker and Trays are removed one at a time and placed onto a FlexLink conveyor system. The Tray is transported first to a Video Microscope where the operator visually verifies the wire bonds are present, then to a Dispensing station where Sil-Gel is applied to each of the 10 Torque Sensors. Once the Sil-Gel has been dispensed, the Tray is transported to the second cure oven where the Sil-Gel is cured. The parts then pass under a cooling fan and are then loaded onto the Automatic Assembly Dial via an IAI Servo Gantry. Once loaded onto the Part Nests the lid of the part is folded over into position to close the Sensor. Once folded the Sensor has two Rivets placed and formed via a Chicago Riveter to secure the Lid of the Sensor. The Force and Travel of this motion are monitored to ensure proper placement of the Rivets. A label is then automatically applied via a Bradley Labeler. The part is then subjected to several tests including a Resistance Test, a Capacitance Test and a battery of functional tests. All Assembly and Test functions are monitored throughout the process via Bar-coded labels, storing the data via a Lab View software package.

Bottom Line -
Due to the ability to work closely with the customer, Baker Group is able to minimize the cost of the system and deliver the Assembly Cell in a very short lead-time to accommodate increasing production requirements.

Electronics Industry - Case Study #2312

Application -
Automatic Testing and Marking of a Sensor utilized to monitor the Speed of a transmission in a Harley Davidson motorcycle.

Challenge -
Simultaneously Test two Assemblies at one time while Marking Parts and recording Data via Lab View Software.

Solution -
Provide a Custom designed Test Station with the ability to Test two Assemblies at one time. Parts are manually loaded into two Quick-Change Fixtures and the Cycle Start Button is initiated. Sensor and Cable Assemblies are inspected for Functionality, Resistance, Capacitance as well as Part presence including Grommets, Clips. Once Tested the parts are engraved via a Telesis Engraving Head. The data is then recorded and collected via a Lab View Software Package.

Bottom Line -
Due to the Automatic Testing of the product the customer is able to 100% test all products prior to shipping.