The Challenge
Delivering Aerospace-Quality Valve Assemblies with Zero Margin for Error
The aerospace valve manufacturer needed to produce highly precise servo valves under strict quality standards. Their objectives included:
- Assembling complex EHSV subassemblies with zero defects
- Integrating testing after each assembly station
- Consolidating multiple processes—assembly, storage, welding, and testing—into one system
- Ensuring traceability and uniform part quality at each build stage
MWES was selected for its ability to design a multi-robot, multi-process line that maintained aerospace-grade precision and scalability.
The Solution
Fully Automated Assembly Line Integrated with Testing, Welding & AS/RS Storage
MWES developed a line that brings together five floor-mounted robots, four track-mounted robots, laser welding, EDM, and automated testing across three assembly cells:
- Armature Subassembly & Test Cell for initial build and validation
- Torque Motor Subassembly Cell with inline test verification
- Valve Body Final Assembly & Test Cell combining subassemblies through 11 precise steps
- Integrated EDM machines, laser welder, industrial oven, and AS/RS system for part handling and storage
- Automated data capture and assembly traceability at each stage
This full-line system enables streamlined flow from subassembly to final testing—with minimal operator involvement.
The Results
Aerospace-Grade Assembly Throughput with Traceable Quality Controls
The MWES system delivered robust performance improvements:
- Fully automated build and test workflow for EHSV production
- In-line validation at each assembly station to ensure zero errors
- Consolidated multiple production steps into one integrated process
- Enhanced traceability through system-wide data logging
With this automation, the customer can produce complex valve assemblies reliably, efficiently, and with complete confidence in quality control.
