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Main features

Initial assumptions

The aim of the project was to develop and build a main assembly line for gas springs with all the necessary functionalities for gassing and functional testing. The assumptions were made that the line was to occupy as little space as possible and involve minimal service. Our advantage in this case was our experience in the automation and robotization of processes related to the production of shock absorbers and gas springs.

Robotization of the gas springs assembly

Limiting the space occupied by the line and reducing the service, but at the same time ensuring the desired OEE value, we decided to solve by robotizing the entire process. Two types of robots have been proposed – SCARA – for fast component feeding and 6-axis robots for operating in the area of ​​the gas filling, testing and unloading module. A number of manipulation axes were also designed, enabling the correct course of the process in the number of 34. The whole was linked by a fast CC Link IE Field (1 Gbps) network.

Modular line structure

• 1. Module 1 – loading the piston rods
• 2. Module 2 – loading cylinders
• 3. Module 3 – piston rod assembly
• 4. Module 4 – spring assembly
• 5. Module 5 – gassing and spring test
• 6. Module 5 – unloading

Summary

Work on the implementation of this project is a great example of good cooperation with global suppliers of solutions in the field of automation and robotization. In this particular case, it was Mitsubishi Electric. It was decided for full hardware compatibility and large configuration possibilities, especially when it comes to servo drives. The assumed properties of the line were achieved, including the reduction of the occupied space by approx. 40% in relation to typical solutions. Thanks to robotization, the necessary line maintenance has been reduced from 5 to 1 operator.

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Line 1

Line 2

Manufacture of zirconium nozzles

Zirconium inserts, also known as zirconium nozzles, are an important product for the foundry industry, used in continuous casting of steel. They are made in the powder pressing technology. The key parameter for the end customer is the inner diameter of the nozzle, measured with an accuracy of hundredths of a millimeter. From the point of view of safety and quality of the casting process, the consistency of the structure of the nozzle material is no less important. The insert must withstand the extreme conditions of many hours of operation at temperatures above 150° C and remain resistant to erosion and temperature shrinkage.

All the above conditions had to be taken into account in the work on creating a technological line for the production of nozzles. The assumption was to minimize human handling and to take into account the key processes: powder pressing and annealing in the furnace. Already at the beginning of the work it became clear that two lines should be created.

• Line 1 – after pressing, nozzles are milled and laser marked, and then palletized by a robot in an appropriate manner before transport to the furnace
• Line 2 – after annealing in the furnace, the nozzles are unloaded (depalletizing) and transferred to the vision quality control station, then to the packing and unloading station

Line 1 – milling, marking and palletizing

The nozzles are loaded by transport from the press. The reloading manipulator translates them onto the turntable. The table ensures the transport of components successively through the laser marking station and the milling station. The MJC Mini dust collector provides the extraction of dust generated in the process. After milling and unloading from the rotary table, a visual check of the geometry is carried out. Items with the OK status are transported to the palletizing station. The palletizing robot is equipped with a gripper with a vision system. It creates an appropriately shaped, multi-level stack, using plates, posts and dividers from a magazine with a system of automatically extended drawers. The palletizing area is secured by the EFAFLEX high-speed roller door. The finished stack is transported by the operator to the furnace.

Line 2 – depalletization, packaging and labeling

After heat treatment in the furnace, the complete stacks go to line 2. The assumed maximum temperature of the components going to the line is 50C. The depalletizing robot decomposes the stack. The auxiliary elements go to the appropriate magazine drawers, the nozzles are put on the transport, which directs them to the turntable of the vision control station. After passing the inspection and unloading from the turntable, the nozzles are packed. The task of the second robot is to complete the packaging in the form of a box, trusses and washers, and to insert the nozzles. The complete box with nozzles passes to the labeling station and is then closed, glued and ready for collection. The line entrance is secured by an EFAFLEX high-speed rolling door.

Summary

Thanks to the use of robots, manipulators, and an appropriate storage system for palletizing and depalletizing, a process line was built with minimal personnel handling, which was reduced to transporting the stack to / from the furnace. Automated milling and vision inspection stations ensure the necessary repeatability and quality of production. The whole is complemented by the Monitoring / Traceability application (currently part of TOMAI Factory System). The application that communicates with the PLC is an important element in tracking parameter changes and quality results.

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Main features

Assumptions

At the stage of collecting input data for line design, designers and constructors of ELPLC S.A. they consulted the concepts and technical parameters of individual stations on an ongoing basis. Process engineers of dampers factories located all over the world expected a universal machine that would allow the installation of various dampers references. It was also noted that the manufactured dampers have pipes with a diameter of 30 to 60 mm, with a height between 120 and 600 mm. It was necessary to take into account different diameters (from 30 to 300 mm) and the position (from 25 to 100 mm) of the spring bed ring. Individual stations and transport routes of the line had to work with the finished product with a height of 300 to 1000 mm. Additionally, the necessity to maintain a specific gas pressure in the damper (from 0 to 25 bar) and the correct gas force in the damper (from 20 to 500N) was emphasized. In addition, the assembly process required working with pads of various diameters (40-80 mm) with a maximum weight of components of up to 8 kg.

There was a need to meet a number of additional requirements in terms of maintaining parameters such as force (45-150kN), as well as the damping force of the damper (-6500 – 6500N), occurring in its appropriate working position (from 0 to 400mm). It was necessary to keep the speed requirements (from 0.5mm / s to 1000mm / s).

In addition, factory representatives emphasized the need for the control line to perform the basic dimensions of the damper.

Summary

A completely autonomous and robotic assembly and testing line was achieved. In principle, it does not require any operator support. The transport of dampers or gas springs to the line is carried out with the use of autonomous AMR or AGV vehicles. The loading operation is performed by six-axis robots. Operations are performed at individual stations. After their completion, the line is unloaded onto an autonomous vehicle. The versatility of the solution deserves attention, as the line can be used both for the production of car dampers and gas springs. The line also uses innovative CTS and EPICS stations.

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Main features

Automatic gluing

Gluing processes are not easy to automate or robotic. Properly selected glue must be applied to a specific place or component, then the next one is applied with precisely selected force. In ELPLC, automatic gluing is a process usually inscribed in a larger whole, a technological line on which other assembly activities are carried out and fully automatic quality control. A good example is the assembly line for elements for the e-mobility industry. The client started the implementation of an innovative project involving the production and delivery of a new type of heating elements. The project required the development, construction and implementation of two semi-automatic lines – one for interior assembly, the other for housing assembly (with full automation options), with cycle time requirements of 50s / 12 pieces. In the case of the assembly line, the fully automatic variant was finally adopted. Automated loading of components is carried out with the use of vibrating feeders and high-speed robots. This ensures an optimal supply of components to the station. The operations performed on this line include: assembly of components, automatic gluing with visual inspection of the layer (2 systems), welding (2 stations), and the whole operation is supported by a transport system with manipulators needed to apply glue, rotate components, and reload. Adhesive dosing with compensation, based on a vision system, servo drive and weight, enables the correct application of the layer (dosing precision ± 0.0125 g, drop diameter approx. 1.9 mm), based on the actual position of the component. The correct composition of the adhesive is ensured by a dispensing needle system with a mixing tube with a constant mixing ratio. Servo-controlled dosing pistons feed the substrates into the mixing tube. There are 3 glue application paths. At the next station, a voltage is applied to the metal plate which heats the component to a temperature of about 100-120 ° in order to consolidate the connection. The second auto-gluing system handles the side walls of the component (dosing precision ± 0.005g).

Summary

The use of our knowledge to design the whole, the selection of equipment and its integration, as well as the construction and software of the line, gave the customer the opportunity to manufacture a new type of elements. Thanks to the option of full automation and robotization, the assumed performance parameters and the ability to install 2 elements at the same time were achieved. In addition, the vision system allowed for precise positioning of components, and the full traceability of the process allowed for the maximization of the use of data from the process and a complete quality history. Under normal conditions, the line can operate periodically autonomously, and the role of a single operator is basically limited to supervising the process and ensuring the appropriate level of components on the loading feeders. Thanks to the integration of the necessary stations connected by a transport system within a single layout, we ensured compliance with the standards of efficiency, safety and cleanliness.

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