Automated production lines
- component sequence and orientation control
- reduces installation time
- ensuring assembly repeatability
- increasing operator safety
- tracking used components for assembly and recording process parameters (traceability)
- one line ensuring the possibility of mounting many variants
- solutions fitted to the customer's production volume (MSD)
Cutting incoming components from the supplier in the form of a tape - originally the customer cut the components manually, this method was not efficient and did not deal with the quality requirements.
The cutting process was burdensome for the operator. Impediment of the automation of the process was frequent deformation of components on the tape.
We have designed and manufactured a fully automatic production station that allows cutting the tape of electronic components:
- we have introduced a tact time of 0.5, while ensuring high precision cutting - up to 0.1mm, which allowed to increase the efficiency of the process while maintaining the right quality parameters;
- the station was equipped with a vision system KEYENCE to recognize potential damage to the batch material, which allowed to protect the machine and final details;
- we have developed a comprehensive design of the cutting mechanism and guide sockets as well as a tape feeding system.
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In the station, we used the SIEMENS PLC controller and FESTO pneumatics."
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We have completed a comprehensive installation at the customer, we provided support during the configuration of process parameters.
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We have created complete documentation (including risk analysis) and a user manual.
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After commissioning the tests, the CE certificate was granted .
As part of the transfer of production between plants, the customer needed new production lnie. The new construction had to deal with Industry 4.0 standards and design capacity assumptions.
We designed and delivered a full production line for vacuum pumps. The line consists of 12 stations that allow to maintain the set assembly cycle and the free flow of details through the line and, thanks to the integration of vision systems ensures correct assembly, in addition all process parameters are recorded (TOX, Baltech) - control function.
The line we created allows for the assembly of several pump variants, that is why there is an active Poka-Yoke system on each socket, taking into account the least time needed to change the line (proximity sensors, replaceable sockets + software with feedback for the operator). The line design included the ergonomics of individual workplaces.
We used SIEMENS PLC controllers allowing communication between individual stations using the Profinet network:
- we have introduced safeguards for the process stages (the line will not allow (+ communication) to the operator to skip assembly steps)
- we have introduced software and monitoring (HMI) enabling communication with the operator;
- The KEYENCE vision system integrated by us provides control over the correct assembly;
- we introduced the TOX pressing system, which gives process control and full integration with the assembly line;
- we used the BalTech rotary pressing system ensuring process control;
- we used an oil spray system using Vectolub SKF micropumps;
- the software we have created allows for step-by-step sequences and checking of control functions - master parts
- We have implemented a communication system with a central treacebility base (registration of process parameters for each piece mounted on the line) - PC and LabView software
- We used FESTO pneumatics to build the line, thanks to which we provided the customer with quick service or equipment replacement if the need arose
- The pallet system implemented by us allows for free and safe flow of details on the line.
- The device deals with the safety directive (limit switches, current protection)"
- We have completed a comprehensive installation at the customer, we provided support during the configuration of test parameters.
- We have created complete documentation (including risk analysis) and a user manual.
- After commissioning the tests, the CE certificate was granted .
