Case Study - Assembly Automation

FULLY AUTOMATIC ASSEMBLY OF AN AUTOMOTIVE LATCH ASSEMBLY

Challenge

A high volume automotive manufacturer, Southco Manufacturing, presented TQC with a number of parts and asked for a machine to automatically assemble them in a short cycle time.

The component, a glovebox latch, is produced in various formats to suit different applications and the overall production volume requirements meant that assembly time had to fit with injection moulding time.

Solution

Based on the system requiring minimal operator involvement, TQC designed and manufactured a fully automated linear assembly system based around a Flexlink conveyor loop with 8 stations.

All parts are bowl fed from bulk and allow the assembly to be sequentially built up along the different stations.  Following assembly the part is fully tested with passed parts marked.  Passed and failed parts are automatically unloaded.

The system is PLC controlled and includes a HMI.  A guard enclosure, including roof, is installed for safety and noise reduction.

Key Benefits

The system ensures that all assemblies supplied to the end customer are correct as integrated testing is included.  Labour costs are at a minimal as a service operator is all that is required, manual assembly would require typically 6 operators.

To read more click here.
View machine video here.

Case Study - Leak Testing

AUDIT LEAK TESTING OF A BRASS CAST PRODUCT

Challenge

To supply a High Pressure Audit Leak Test System with the ability for PC Datalogging. The customer required an alternative to testing parts under water for the quantifiable leak testing of their cast brass components.  An addition need was for all results to be logged via a PC.

A number of variants need to be tested using high pressure nitrogen inside the product. 

Solution

TQC supplied a system based around their standard leak test solution. This includes a self-guarding drawer leak test fixture and a leak test instrument.

Customer parts are loaded into interchangeable tooling within the leak test fixture, the drawer is closed and the leak test automatically started.

The testing includes a gross leak test to ensure the instrumentation is not damaged and a fine leak test to ensure the part does not leak in excess of the pass/fail parameters set.

The leak test used -0.2bar vacuum external to the part and 34bar nitrogen internal to the part with an air leakage limit of 50 cubic mm per sec.  The test was completed in around 25 seconds.

The data logged by the system included batch data, part number, die number and test results.

Key Benefits

The customer gained a facilty for the quantifiable leak testing of their product.  The system can accomodate part variants easily via interchangable 'drop-in' tooling inserts. All test results are automatically logged for any tracking purposes that are required.

To read more click here.

Company Experience

The information below is just a selection of the wide range of experience TQC has gained over the past 20 years.

Automatic Assembly  

• Pallet Based Systems
• Rotary Table Solutions
• Indexing Systems
• Bowl Feeders
• Pick & Place Technology

Integrated Testing  

• Leak Testing (air decay, helium)
• Pressure / Burst Testing
• Poka Yoke Assembly Checking
• Function Testing
• Electrical Testing
• Hydraulic Testing
• Vision Systems

 Automated Handling & Robotics  

• 6-Axis & SCARA Robot Systems
• Conveyors Systems
• Pallet / Tray Loading & Unloading

Jigs & Fixtures  

• Welding & Machining
• Assembly & Test Fixtures
• Measurement fixtures

General  

• Full Mechanical, Electrical & Software Design
• Fully Managed Projects
• In-house Manufacture, Painting, Electrical Panel Build
• Installation / Commissioning & Full Service Backup
• GAMP, 21 CFR Part 11