We continue to innovate in our machine designs, build processes and programming techniques. Our teams cross-functionality sets us apart. We look forward to creating your next automated assembly or test system.
Test equipment is one of our specialties. The image shown is a Two station dial test machine. It has several manual operations along with Automated operations with the use of a Fanuc Robot. We are specifically testing a small part assembly that is within a steering column. Its main testing purpose is to be sure that the small assembly is able to move to all of the available shift positions within the column. A multi-direction loadcell is used, along with a specialized camera guidance solution mounted to the Fanuc Robot. This assists us in validating proper part position prior to tool insertion. We are also installing a screw with an Atlas Copco torque driver. We measure torque and angle of the screw during installation. This validates that the screw has been installed properly and that the specified parameters have been met.
Mechanism assembly is a critical process. Many factors drive the required quality requirements while assembling mechanisms. Safety is top on the list as many mechanisms are critical components relating to functionality during unforeseen incidences. Mechanism functionality for high cycle rates is another factor that drives the importance of the assembly process. We are conducting several pressing and forming operations utilizing Hypercyl Press heads along with lubrication, labeling for traceability, and finally a testing operation to ensure that the mechanism is working properly prior to moving to the next station. We are monitoring press force and distance in the assembly operations. The testing operation is monitoring the torque and angle of rotational travel of the mechanism.
Forming rivets with this ten-station dial allows for manual loading at two stations, auto rivet forming at four other stations and then a final auto unload once the part is complete. We use overhead cameras to inspect part loading per the selected configuration. This allows for multiple assemblies to run on the same dial without any tooling changeover. Cycle lights help the operator understand the current process state of the machine. It will identify if parts are loaded properly. They will also help the operator understand if there is a fault in the sequence of operations.
Laser welding of mechanisms is a critical process. Multi- layer assemblies are laser welded together in this machine. Lasers do generate a localized heat focal zone. During the debug and runoff phase of the machine building process we also have the capability in house to cut and etch the part assemblies to validate proper weld penetration and quality. The robots in the image are automatically loading and unloading the parts onto the dial table. Proper guarding and ventilation are critical due to safety requirements.
This is a two-station press. Multiple part configurations can run on each side. It is a manual load and automatic unload for good parts. If the part faults during the monitoring of the press sequence, the press head will stay in the down position and will have to be manually released through the HMI panel. Once the head is released the part will be manually placed in the reject chute with a sensor detecting the part as is enters the reject box. Each side of the machine can run independently. Two, part bins are on conveyors below the machine. One for the left and one for the right. Once the bin volume count has been met, the part bins are automatically released to the next station.