The Challenge
Reducing Operator Dependency and Ensuring Fast, Error-Free Assembly
Relying heavily on manual labor for part assembly created staffing challenges and throughput inconsistencies. The customer needed an automation solution that could:
- Automate ultrasonic welding of acoustical materials into cover interiors
- Precisely insert rubber grommets and push nuts into pre-drilled holes
- Integrate vision-based inspection for final quality control
- Seamlessly reject failed parts while preserving production rate
MWES was selected based on its experience integrating robotic assembly, inspection, and defect handling in automotive environments.
The Solution
Multi-Robot Work Cell with Integrated Welding, Fastening & Vision Inspection
MWES engineered a comprehensive robotic automation cell featuring:
- Two Fanuc LR Mate 200iC/5L robots and one M10iA/10kg robot for ultrasonic welding, grommet insertion, and testing
- Flex‑Link pallet conveyor system to index engine covers through three robotic stations
- Ultrasonic welding to attach acoustical insert, followed by fastening grommets and push nuts
- Vision inspection via camera to conduct final pass/fail analysis
- Automated reject gripper to divert failed parts and unload good units to the exit station
The system orchestrates assembly, fastening, inspection, and rejection in a streamlined flow—reducing operator intervention and ensuring consistent quality.
Summary: This turnkey robotic cell automates all post-manual operations, combining ultrasonic welding, fastening, visual verification, and reject sorting in a fast and reliable production loop.
The Results
Consistent 60‑Second Cycle, Fewer Errors & Operator-Free Rejection
The implementation delivered measurable operational benefits:
- Achieved a reliable ~60-second cycle time per part
- Reduced dependence on manual labor while supporting high operator turnover
- Consistently accurate ultrasonic welds and fastener installation
- Automated quality inspection and reject handling without manual sorting
By automating critical assembly and inspection steps, MWES provided a high-throughput solution that improved reliability, reduced labor demands, and ensured consistent part quality.
