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Custom Engineered Solutions
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Customer Objective
Design and install a new, fully automatic assembly and test system to assemble multiple models of sprag style, automotive clutch assemblies. A single machine chassis is desired with a pair of synchronous transfer systems coupled by an accumulating conveyor.
Model change-over requirements include both automatic and manual operations with tooling and position feedback at all set points to verify correct model setups.
Project Description
Cam operated lift and carry systems are equipped with pneumatic, large-range grippers to transfer assemblies in sequence from one operation to the next. Using a combination of adjustable feeders, multiple set points and three sets of tooling, the system is able to assemble four sprag clutch models.
Each station is supplied as a modular unit with the ability to change and verify that the selected model-specific tooling is in place and that part supply magazine configurations are setup correctly for the for the model in production.
The assembly and test operations include: automatically accumulate and feed outer and inner races on conveyors, magazine feed washers, end caps, snap rings, and sprag sub-assemblies, automatically vision inspect the orientation and position of each sprag in the sub-assembly, check inner race rotation effort, inspect the sub-assembly stack height, apply a push-out check on completed assemblies; automatically unload completed assemblies while separating the rejects and finally, mark, unload and accumulate all accepted assemblies.
Manufacturing Benefits
Reduced over-all floor space required using a single machine platform.
Improved material handling efficiency and placement accuracy at all operations was obtained through the use of automatic tooling, feeding and transfer systems.
An increased over-all system operating capacity was realized by integrating part feeding magazines and buffer storage systems with the ability to handle large quantities of parts, maximizing the replenishment and packing time intervals.
Integrated Technologies
Servo Motion Control, Integrated Vision Dimensional and Profile Inspections, Dot-Peen Impact Labeling, Robotic Material Handling, Cam Indexing/Servo Elevated
Magazine Parts Feeding, Synchronous Part Transfer System, Part Buffer Accumulation,
Snap Ring Insertion, Hydraulic Pressing, Localized I/O Fieldbus Communications,
Allen-Bradley PLC and Operator Interface Terminals.
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