The Challenge
Manual Trigger and Bottle Assembly Was Labor-Heavy and Inconsistent
The customer needed to automate a multi-step assembly process to keep up with demand and improve quality. Specifically, they needed to:
- Sort and orient diverse trigger types moving on a conveyor
- Pick and torque triggers onto filled bottles within tight tolerances
- Weld triggers to bottles ultrasonically for secure bonding
- Integrate quality checks without disrupting high-speed throughput
MWES was selected to develop a turnkey solution capable of handling complex component coordination with automated reliability.
The Solution
Vision-Guided Robotic Assembly with Torque and Ultrasonic Welding Integration
MWES delivered an advanced assembly line incorporating robotics, vision, and high-precision controls:
- Trigger sorting via hopper and flighted conveyor systems
- Dual-robot vision-enabled pick-and-place for trigger orientation and placement
- LinMot actuators for precise trigger handling and placement sequence
- Dual servo feed-screw conveyor control for bottle positioning
- Controlled torque system for trigger closure and ultrasonic welding for assembly finalization
TWelded robots place triggers accurately onto bottles, which are then secured and ultrasonically welded to ensure quality and consistency.
The Results
5‑Second Cycle Time, Full Validation & Labor-Free Operation
MWES’s automation solution delivered substantial gains in efficiency and reliability:
- Assembled and verified each bottle-trigger set in 5 seconds or less
- Enabled 100% inspection of torque closure and weld quality
- Eliminated operator dependency for an otherwise complex manual task
- Supported consistent quality and high uptime in a fast-paced production line
By integrating robotics, vision, torque control, and ultrasonic welding into one streamlined cell, MWES enabled full-system automation of a high-mix assembly process.
