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Custom Engineered Solutions
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Customer Objective
Design and install a new, complete manufacturing system to assemble, test and label a medical device with sound ergonomic principles and in-process checks to verify that all components in the assembly comply with rigid quality standards. Recording the data from post process testing operations is required on 100% of the devices and is used to verify that the operating parameters are within established limits.
Project Description
A manufacturing system employing lean cell technology includes a main assembly machine that is supported with post-process testing equipment. The assembly machine incorporates an indexing dial to transfer assembled components in fixtures between operations in a synchronous sequence. Manual loading operations are coupled with machine vision systems to verify that the correct components are loaded and assembled properly. Pressing operations are pneumatically operated and monitored to ensure the forces and distances the tooling travels are within the process limits. Accepted devices from the assembly system are permanently labeled with a serialized number and model identification from a LASER marker and vision inspected before entering post process testing.
Post process testing requires component parts be radially aligned with a servo controlled axis integrated with a vision system. Subsequent vision inspections verify the device is within dimensional specifications. Functional testing then verifies that resultant forces from a variable input load meets the design criteria and lastly, the device is electrically tested in a system that automatically connects, tests and disconnects.
Manufacturing Benefits
The new system transfers components through the assembly process while being held in dedicated fixtures. The configuration of the device is not stable until all assembly operations are completed. Due to this instability, the device is impossible to assemble by hand.
A self calibration routine was developed and integrated with the press system to automatically calibrate the force and distance monitoring equipment during scheduled intervals.
Post process testing is included in the assembly cell to verify that the device complies with rigid operating and functional quality standards.
Integrated Technologies
Servo Motion Control, Integrated Vision Dimensional and Profile Inspections, LASER Marking System, Press System Force and Distance Transducers with Automatic Calibration, Cam Indexed Synchronous Transfer System, Input Force, Reaction Force and Electrical Testing, Allen-Bradley PLCs and Operator Interface Terminals.
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