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Assembly Dial Applications
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Casting Industry - Case Study #2405
Application -
Streamline and control the assembly of a High Volume Casting Body and Steel Tube for use in High Pressure Water System.
Challenge -
Application requires applying a Lock-Tite Sealant to the inside Bore of a Machined Casting and the Insertion of a Steel Tube inside the Bore as well as application of a Three Bond material to the Casting.
Solution -
Assemble product through the use of a 6 station Automatic Assembly Dial. The Operator Loads the Casting and Tube. The Second station will automatically apply Lock-Tite to the I.D. of the Casting. The Third station will automatically verify proper amount of Loctite Material has been applied. The Fourth station will Pick up the Steel Tube and Press the tube to the proper depth via a Schmidt Press Unit. The press unit monitors the Force and Depth at which the Tube is Pressed. The Fifth Station consists of a Fisnar Robot which automatically applies a Three Bond material to the Casting Body. The Sixth and Final station removes the Sub-Assembly from the Dial and places on a finished parts conveyor or Reject bin depending on feedback from the inspection features of the machine.
Bottom Line -
Due to the automatic assembly and inspection of the product the customer has improved production 300% and cut scrap production by 25%, consistently delivery product to the end customer in a timely basis.
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Window Hardware Industry - Case Study #
3605
Application -
Develop a semi-automatic assembly method to increase output of a Window Lock that may double in volume over the next few years.
Challenge -
Automatically Assemble lock by dispensing Lock-Tite material to a zinc die cast part and drive fastener into place to allow proper function of the Lock upon completion of assembly.
Solution -
Design and build a custom twelve Station assembly dial. The operator loads the plastic body and Zinc Lock plate into position on Pallet. The second station verifies presence of all components. The third station applies Lock-Tite to the Plastic actuator handle. The fourth station automatically drives a screw into position into the Plastic Crank handle while monitoring torque and angle. The fifth station automatically unloads the assembly onto an offload tray.
Bottom Line -
The machine dramatically increases the quality of the completed assembly with the automatic Lock-Tite dispensing and automatic Screw installation. The machine was designed with future capacity in mind. With the leftover six stations an additional operator and stations can be added to double production in a matter of weeks.
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Electronics Industry - Case Study #2506
Application -
Provide a low cost semi-automatic Assembly and Test System to Solder, Crop, Test and Inspect a wound Bobbin.
Challenge -
Automatically and consistently applying Solder to Terminals Ends via a Dip Solder method while constantly monitoring the integrity of the process.
Solution -
Assemble product through the use of a 12 station Automatic Assembly Dial. An Operator Loads the Sensor at the first station, Optic Sensors verify the correct orientation and correct part prior to index. The Second station will automatically apply Flux to the ends of the terminals for solder adherence. The Third station will automatically raise a Solder ladle to the terminal ends and apply solder to the terminals. The Fourth station will Crop the ends of the Terminals. The Fifth Station automatically verifies the proper Resistance and Capacitance of the sensor. The Sixth station consists of a DVT camera, which verifies proper solder coverage and integrity of the operation. The Seventh station removes the Assembly from the Dial and places into a Reject bin depending on feedback from the inspection features of the machine. The final station removes all good parts from the system and places onto a Dorner transfer conveyor.
Bottom Line -
Due to the automatic assembly and thorough part inspection of the product the customer has improved production and cut scrap production.
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