Case Study 312A
Automotive Hinge Assembly
Characteristics
- modular Smart Cells, completely controlled and operated within semi-automatic assembly line
- one semi-automatic parts loading station
- one manual parts loading station
- 8 fully automatic operating Smart Cells
- custom developed gantry robot for loading and unloading of punching press
- 12 second cycle time : 4-up assembly mode
- two parts variations with changover fixtures and tooling
Processes Integrated into Machine
- automatic parts feeding with vibratory bowl feeders and blow feeders
- pick-and-place and parts manipulation in 3D space
- air-over-oil press insertion, flaring, and staking operations
- orbital riveting
- LVDT parts measuring
- servo driven gantry robot covering four meter travel distance
Challenges & Accomplishments
- limited space requirement met
- performance requirement achieved
- gantry robot traveling long distances for loading and unloading parts into press
Case Study 12301/302
Automotive Door Checker Assembly
Characteristics
- cam driven linear indexing machine
- entirely sychronized motions via cam shaft
- two machines with 18 fully automatic stations
- high speed performance: up to 30 cycles per minute
Processes Integrated into Machine
- cam driven pick-and-place
- automatic parts feeding
- air-over-oil staking and crimping operations
- LVDT parts measuring
Challenges & Accomplishments
- durable, precise, high-performance machines
- in operation since 1995
- 4 very similar lines have since been built
Case Study 314D
Automotive Fuel Line Assembly & Testing
Characteristics
- Height adjustable frame
- Easily accessible components
- Loading and unloading assists
Processes Integrated into Machine
- Leak testing
- Clip assembly
- Convolute and Mesh Sleeve checking
- Bracket folding and crimping tool
- Greasing operation with 90° swivel tools
Challenges & Accomplishments
- Tools developed for tight space constraints
- Ferrule checking integrated into leak test tools
Case Study 308006
Automotive Plug Seal Assembly & Testing
Characteristics
- single station assembly machine
- manual parts loading
- automatic assembly and testing processes
Processes Integrated into Machine
- leak testing
- flow test with low pressure
- servo driven assembly motions
- vision inspection of all components
Challenges & Accomplishments
- only two pneumatic and one servo motion used for 7 processes
- highly efficient
- programmable and expandable
Case Study 313P
Automotive Fuel Line Assembly
Characteristics
- manually loaded assembly and testing cells
Processes Integrated into Machine
- leak testing
- bracket crimping
- various clip assembly and closing
- label printing and colour sensing
- convolute, sleeve & tape checking
- localized guarding
Challenges & Accomplishments
- 3D parts geometry
- tooling mounted adjustably in space to accommodate parts tolerences and deviations
- modular tooling design
- "future use" base machine concept: allows for easy upgrades and retooling
- "easy access" base machine system
Case Study 313D
Automotive Transmission Line Assembly
Characteristics
- manually loaded assembly and testing cells
Processes Integrated into Machine
- leak testing
- bracket crimping
- various clip assembly and closing
- label printing and colour sensing
- convolute, sleeves, tapes, and similar parts checking
- localized guarding (instead of light curtain) where possible
- verification of ferrule crimps
- pal nut assembly
- greasing application
- shipping cap assembly and checking
Challenges & Accomplishments
- ergonomic requirements due to 3D parts geometry
- tooling adjustability required for handling of several product variations
- modular tooling design
- "future use" base machine concept : allows for easy upgrading and retooling
- "easy access" base machine system
Case Study 311003
Locomotive Brake Handle Tester
Characteristics
- testing machine to measure forces of handle activation
Processes Integrated into Machine
- entirely servo driven (no pneumatics used)
- fully programmable
Challenges & Accomplishments
- all motions and processes required operation without use of pneumatics
- precise accuracy force measurement required
Case Study 313B
Hybrid Automotive Sensor Tester
Characteristics
- machine to test lifetime of automotive level sensor
Processes Integrated into Machine
- electric drive system with mechanical oscillator functions
Challenges & Accomplishments
- very high performance - cycle testing at 50 Hz (5o cycles per minute)
- overcoming high inertia in mechanical system at high speed
- drive and mechanical systems to withstand the product life cycle at high performance
