Automated Assembly System
Midwest Engineered Systems Inc. designed, developed and installed an automated assembly system for an injection molding and prototyping company. The final system was a completely automated system that moved un-assembled parts through three assembly operations.
- System must perform the following (3) operations:
- Spin weld injection molded port to water outlet body
- Install multiple brass compression limiters in water outlet base
- Perform leak testing of completed assembly
- System must include capacity for future additions
- System cycle time of 35 seconds or less part to part
After a full evaluation of the project’s challenges and goals, Midwest Engineered Systems provided the customer a complete solution, that included:
- Robotic Dunnage Unload: Material handling robot uses a 2D machine vision system to roughly locate the part in dunnage and pick the part from dunnage. The robot places the part in a re-grip stand where the robot then precisely re-grips the next part for the next operation.
- Spin Welding Station: Robotic automation moves the part to the spin welder to weld port onto the assembly.
- Pallet Load Station: Material Handling Robot then loads spun welded part onto a pallet conveyor system. The pallet containing the part is lowered and released into the automated assembly and inspection system.
- Compression Limiter Install Station: Pallet is raised and locked into position. Limiters are blow fed to a gantry robot gripper. The limiter is then pressed into position. During this manufacturing process, a total of 4 limiters are installed. The pallet is then unlocked from the assembly station, lowered onto the conveyor, and released.
- Leak Test and Marking Station: First, the pallet is raised and locked into position. All necessary ports are automatically plugged and the part is subjected to pressure testing for leaks. The laser will mark part with a date code for good assemblies. The pallet is unlocked, lowered onto the conveyor, and released.
- Vision Camera System: Pallet is raised and locked into position. The 2D vision system inspects the part for correct assembly. The machine vision inspection system also checks for gross material defects, as well. The pallet is unlocked, lowered onto the conveyor, and released.
- Unload Station: Pallet is raised and locked into position. The robot will unload the assembled part from the pallet conveyor system and place good parts into the outgoing dunnage. Parts that fail the leak test or vision inspection are loaded into a reject chute for disposition by an operator.
Impact to the Customer
The final assembly automation system provided the customer with the following benefits:
- The automated system offers higher quality production through integrated vision inspection systems
- The MWES manufacturing automation system has built-in flexibility for future expansion
- The robotic automation offers the ability to achieve a virtual “lights out” manufacturing operation
For more information on this equipment or other web handling needs please contact MWES.