Automating the cutting of PCB fixing clips at Diehl

Company overview

Diehl is an international supplier in the electronics industry, recognised for its commitment to quality and innovation. Among its diverse product range, Diehl manufactures PCB fixing clips, which are essential components in electronic assemblies.

Executive summary

The implementation of the automatic cutting station has delivered substantial benefits for Diehl, including:

• Increased production efficiency and consistent product quality.
• Reduced operator workload and improved workplace ergonomics.
• Enhanced process reliability and machine protection.
• Full regulatory compliance, supported by comprehensive documentation and CE certification.

‍

Project objectives

To address production bottlenecks and quality concerns, Diehl set out to:

• Automate the cutting of incoming components supplied in tape form.
• Increase process efficiency and precision.
• Reduce the physical burden on operators.
• Ensure consistent quality and protect against component deformation.

The challenge

Previously, Diehl’s operators manually cut components from the supplied tape. This method was inefficient, failed to consistently meet quality requirements, and was physically demanding for operators. Frequent deformation of components on the tape further complicated the process and hindered automation efforts.

The solution

A fully automatic production station was designed and manufactured to address these challenges. The solution included:

• Achieving a tact time of 0.5 seconds, with high-precision cutting up to 0.1 mm.
• Integrating a KEYENCE vision system to detect potential damage to batch material, protecting both the machine and final components.
• Developing a comprehensive cutting mechanism, guide sockets, and a tape feeding system.
• Implementing a SIEMENS PLC controller and FESTO pneumatics for reliable automation.
• Providing complete installation, process parameter configuration support, and full documentation, including risk analysis and a user manual.
• Securing CE certification after successful commissioning and testing.

Key achievements

Significantly increased efficiency

The new station operates with a tact time of 0.5 seconds, greatly improving throughput.

High-precision cutting

The process now achieves cutting accuracy up to 0.1 mm, meeting strict quality standards.

Enhanced process reliability

The vision system ensures early detection of material defects, reducing the risk of machine damage and improving final product quality.

Improved ergonomics and safety

Automation has eliminated the burdensome manual cutting process, reducing operator fatigue and risk.