Przemysł Przyszłości – przekrojowy, inspirujący i praktyczny warsztat dla menadżerów przedsiębiorstw

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4-5 grudnia 2019 r., Stawiguda koło Olsztyna, ul. Piaskowa 7

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Tag Archives: robotized soldering

Robotized assembly line for satellite TV tuners

Other realizations:

9 August 2022
22 March 2021
16 December 2020
3 November 2020

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Robotized assembly line for D – profiler frames or die cast housings with PCBs with use of an automatic screwdriver and solder elements in place with use of Alnea’s Zeus Soldering Set and Horus Vision System 3d Positioning For Robot .
Elements’ transport inside and between line’s stations, screwing and soldering processes are executed by three 6 – axis robots. Line is equipped with Balluff safety systems and a safety cages, preventing interference of outside conditions or a third party.
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Suited for client

The line is equipped with two types of dedicated box magazines. Both types have adjustable width and depth to accommodate various components.
Robot picks die cast from the box magazine and moves it under thermal paste dispenser to put the paste on the designated spots.

Three robots – complex assemblye

VEKL0005 line consists of two stations:
1) storage and preparation of components equipped with robot KUKA KR6 R900-2
2) screwing (KUKA KR6 R700-2) and soldering station (KUKA KR3 R540)
Die cast housing or D-profiler frame assembled with PCB in station 1 is placed on one of two fixtures integrated with linear drives by Station’s 2 manipulation robot. Elements are held in place by a set of pneumatic actuators during screwing process.
Die cast is moved into screwing position where PCB is screwed to the Die cast housing with an automatic screwdriver integrated with 6 – axis robot. The robot picks screws from an automatic feeder.


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Collaboration of robots

After screwing process is finished, elements are moved into soldering position where connectors’ pins are soldered to the PCB. Soldering process is executed by station’s second 6-axis robot integrated with Zeus soldering equipment.
Zeus’ controller through which the soldering process can be adjusted is located in a cabinet on the front side of station’s A safety cage.

Alea Vision System - Eye for the robot

Finished product is removed from the fixture and placed in a box magazine on the storage rack in station 2 by the manipulation robot.
Components are handled by a robot equipped with a set of Festo grippers and Horus vision system.
Station’s robot scans the rack with Horus vision system to verify proper placement of box magazines and components inside them.

What does operator?

Operator’s task is to monitor the process with use of the HMI panel, refill screws through dedicated chute and place box magazines with components in proper spots on storage rack, monitor handling of components by the robot and remove box magazines with finished and NOK products.

What we can do for you?

What we can do for you? We can design and build production or assembly line. Alnea products guarantee innovative solutions and high precision of manufacturing with use of highest quality, repeatedly tested materials.

We will prepare for you an automatic, semi-automatic, robotic production line. Ask us about Horus Vision System!
write to us as soon as possible:

biuro@alnea.pl

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Robotized assembly station within production line

Other realizations:

9 August 2022
22 March 2021
16 December 2020
3 November 2020

MORE

A very important project in the history  of Alnea was the project of building a production line for the valves for the ventilation system of car seats. One of the most interesting points of the automated line was station 1, which was designed for four KUKA robots working with a rotating production wheel, where the process was kept up, that is, without stopping the wheel. This solution reduced production time by 40%. An additional benefit was the use of 4 instead of the 5 robots required by the Customer, which resulted in a lower station cost.
Another station presents the cutting process, which thanks to the use of a variable geometry stamp reduced the noise level by about 20 DB, which was one of the key requirements on the part of the customer.

 

Soldering robot

The next process on the line is a soldering process based on our solution – ZEUS. The process ends with a video inspection.

At the next station you can see the process of plasmaming or preparing the surface for the application of glue. Note that the second tool on the robot is a dispenser that precisely applies glue.

 

 

The workpiece then passes to the piston (these are components such as springs and rubber bands with a diameter of 3 mm). A robot equipped with 3 tools is responsible for the process of cutting and assembling components with each other and in the next step passes the detail for the second robot, which measures the resistance and after the process is completed, transfers the detail for further production.

 

Plasma station

A cover is mounted on the next station, which is delivered via a vibrating feeder. After the installation of the upper bodywork is completed, the part is transported again to the plasma-adhesive station. In this process, the upper body and the bottom body are connected with glue. According to the customer’s requirements, the adhesive can not be lowered into the lower body, which is why in the next production phase a UV lamp was used, which within 4 seconds hardens the applied layer of glue.

A very interesting and complicated station in this production string was a leak and flow testing station. The tests were carried out using atmospheric air and helium. I would add as a curiosity that helium leak testing was at the level of collecting individual atoms, that is, at an almost laboratory level (in the production cycle of 12 seconds). The measurement results were developed in a dedicated LabView-based application. After the tests have been completed, the detail goes to the last station, where the product marking process (OK/NOK) takes place and is armed with a so-called dumper and handed over to the operator as a ready-made valve for installation or integration into valve blocks.

Summing up 14 robots, 3 shifts, 7 days a week, a minimum of 300 products per hour, quality assurance thanks to 10 video inspection points.

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ALNEA SP. z o.o.
Księcia Janusza 23/10
01-452 Warszawa

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    KLAUZULA INFORMACYJNA

    Zgodnie z art. 13 ust. 1 i 2 Rozporządzenia Parlamentu Europejskiego i Rady (UE) 2016/679 z dnia 27 kwietnia 2016 r. w sprawie ochrony osób fizycznych w związku z przetwarzaniem danych osobowych i w sprawie swobodnego przepływu takich danych oraz uchylenia dyrektywy 95/46/WE (RODO), informujemy, iż:

    1. Administratorem przetwarzanych Pani/Pana danych osobowych jest ALNEA Spółka z ograniczoną odpowiedzialnością, ul. Księcia Janusza 23/10, 01-452 Warszawa.

    2. Pani/Pana dane osobowe przetwarzane będą na podstawie art. 6 ust. 1 pkt a Rozporządzenia Parlamentu Europejskiego i Rady (UE) 2016/679 z dnia 27 kwietnia 2016 r. w sprawie ochrony osób fizycznych w związku z przetwarzaniem danych osobowych i w sprawie swobodnego przepływu takich danych oraz uchylenia dyrektywy 95/46/WE (RODO) w celu związanym z realizacją zapytania zawartego w formularzu kontaktowym, w celu przesłania oferty handlowej.

    3. Odbiorcą Pani/Pana danych osobowych będzie podmiot świadczący usługi IT na rzecz Administratora z siedzibą na terenie Europejskiego Obszaru Gospodarczego.

    4. Dane nie będą przekazywane do innych państw i organizacji międzynarodowych EU ani użyte do profilowania.

    5. Pani/Pana dane osobowe będą przechowywane przez okres nie dłuższy niż jest to celowe, z uwagi na złożone zapytanie zawarte w formularzu kontaktowym.

    6. Posiada Pani/ Pan prawo dostępu do treści swoich danych osobowych, ich sprostowania, usunięcia lub ograniczenia przetwarzania, prawo wniesienia sprzeciwu wobec przetwarzania, prawo do przenoszenia danych, prawo do cofnięcia zgody w dowolnym momencie bez wpływu na zgodność z prawem przetwarzania, którego dokonano na podstawie zgody przed jej cofnięciem.

    7. Ma Pani/Pan prawo do wniesienia skargi do organu nadzorczego, gdy uzna Pani/Pan, iż przetwarzanie danych osobowych Pani/Pana dotyczących narusza przepisy ogólnego rozporządzenia o ochronie danych osobowych z dnia 27 kwietnia 2016 roku.

    8. Podanie przez Panią/Pana danych osobowych jest dobrowolne aczkolwiek konieczne w celu realizacji przesyłanego zapytania zawartego w formularzu kontaktowym, w tym przesłania oferty handlowej.

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