Components Sub-Assembly Line
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.