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Components Sub-Assembly Line
Automotive | Assembly
A customer in the automotive industry needed a second assembly line to handle increased production volume.
TCA's challenge was to use as much engineering as possible from the existing TCA-designed line so the two could efficiently run in tandem. Working from the customer's part specifications, we created 3D designs for all the components and arranged the second line in a Z-configuration to facilitate loading and changeover. In addition, we designed a second flux supply line with a separate set of tooling to enable both lines to operate independently.
Occupying a 20 ft x 30 ft footprint, this assembly line has three main subsystems - a feeder, flux applicator, and a stacker. Handling 6 parts per magazine, 6-axis robots are used to feed the parts to a servo index conveyor for pick and place transfer - a careful process monitored by machine vision cameras.
Next, a dual-head spray system electrostatically applies the flux while a reclaiming system removes the excess. After air drying, the parts are fed to the assembly system, 2 per magazine in a nested position.
This assembly line underwent full functional testing as well as a 4 hour dry-cycle test before it was shipped to the customer in Mexico. In addition to supervising the site installation, our engineers supplied full documentation as well as operator training that encompassed.
Highlights
Project Description
This assembly line is the second assembly line of its type and was made to use as much engineering from the existing line as possible.
Capabilities Applied / Processes
Design & Layout
- 3D Design of all components using SolidWorks
- Configure Line in a "Z" Configuration for ease of Loading and Changeover
- Supply Line w/ a Complete Set of Tooling
- Design All Tooling
- Design Separate Path through the System
Manufactured in-house using our CAD/CAM equipment and capabilities
PLC programming
HMI Design & Programming
Supervision of Site Installation
System Commissioning
Operator Training
- Technical Features and Specifications
- Operation Training
- Recommended Maintenance
- Changeover Procedure
- Recommended Fault Recovery
Documentation
- Hard-Copy & CD-ROM Copies of Manuals
- AutoCAD Assembly Drawings & Schematics
System Sections & Components
Automated Parts Feed System
- 6 Parts Feed Rotary Dial Magazines
- 6 Axis Robot
- Parts Feed Servo Index Conveyor
- Walking Beam Load Pick & Place Transfer
- Cognex Insight 5100 Vision Cameras
- Lexan Perimeter Guarding
- Electrically Interlocked Access Doors
Flux Application System
- Electrostatic Flux Application System
- 2 Flux Spray Head Mounting Arrangements
- Reclaim System to Return Excess Flux
- Air Dryer part Stacking System
- 6-Axis Robot
- Recirculating Pallet Transfer System
- 2 Parts Feed Rotary Dial Magazines
- Intermediate 2-up Nest Position
- Pick and Place Unit
- Stacking Guide
- Recirculating Assembly Build Conveyor
Electrical Control System
- Allen Bradley GuardLogix PLC
- 3 Allen Bradley PanelView Plus 1000 Operator Interfaces
- Main Control Panel
System Features
Tooling ID 2D Barcodes & Barcode Readers
Sequence of Operations
- Singulate and Feed Components
- Load Parts in Predetermined Sequence
- Apply Flux to Specified Parts Group and Assemble Components in Predetermined Sequence
Testing/Inspection Performed
Dry Cycle Testing
- 4-Hour Dry Cycle Test
Functional Testing
Sequence of Operations
- Singulate and Feed Components
- Load Parts in Predetermined Sequence
- Apply Flux to Specified Parts Group and Assemble Components in Predetermined Sequence
Overall Lead Time
30 Weeks
Overall System Dimensions
20 ft x 30 ft