Automated Assembly
The automated assembly of components is becoming more important in the achievement of lower costs, faster production rates and higher first time pass rates. Levels of automation vary from partial operator assistance to fully automatic, operator independent assembly systems.
Fully Automatic Assembly
Fully automatic assembly may be required, due to hazardous operating conditions, speed of assembly required or the operation is required mid process with no opportunity for manual intervention.
Automatic Component Assembly
As part of a larger assembly line, automated independent stations may be introduced to add a variety of components to the product after passing a functional test. These may included banjo bolts, O-rings protection caps, washers, identification tags etc. A simple solution is to load the product to a dial plate and perform multiple operations. For example:
- Press sealing washer onto a seating face
- Fit coloured Identification ring
- Fit protection cap to the component inlet
- Select and fit O-ring and over-check with a vision system for compliance
- Fit a banjo bolt with sleeve before inserting into the component and apply correct torque
- Fit a protection cap on the component outlet
This illustrated solution utilised 7 bowl feeders stationed around the dial plate with a footprint of about 2m x 1.8m.
Multi station, fully automatic final assembly system
Partial assistance with assembly
Partial automation of a process may be necessary to remove potential operator influence from a process where test or measurement is part of a selective assembly process.
Semi-Automatic Assembly - Diesel Injectors
A system was required to improve the assembly and first time pass rate of diesel injectors. Numerous measurements of critical dimensions determined the correct size of shim and mating part to be fitted. Our solution was to minimise operator error and influence by loading the main assembly to a bespoke pallet that formed part of a gauging process, with gauge stations spaced along a linear track, lock the pallet to the track system to prevent it being removed until all the data had been gathered at each station and introduce the correct components from integrated carousels at the gauging stations with a final operation to tighten the assembly to a specified torque before releasing the pallet for functional testing.