Modular machine increases switch production rate

US auto component manufacturers Pressac Inc has ordered a new high-speed assembly and test system from Modular Automation

Leading U.S auto component manufacturers Pressac Inc looks set to increase volume production of its horn-switches for new Toyota, Chevrolet and Pontiac cars with a new high-speed assembly and test system from Modular Automation.

The machine, which is to be exported to Pressac's Alabama plant, combines a high-accuracy indexing table with a tubular riveting process and comprehensive electrical test processes - and for the first time, two reclaimed robots from previous automation projects.

Based around a 1.5m diameter indexing table, the process commences at a manual loading station where two electrical harnesses are placed into position.

Using colour sensors, the harnesses are colour-checked to ensure that they are of correct polarity.

The harnesses are then transported to the horn-switch membrane loading station, where the membranes arrive on conveyor-based pallets and are loaded to the indexing table by a four-axis Sony robot.

Once the membranes are in position between the harnesses, they are then transferred to the riveting stations.

Tiny 4mm rivets are bowl fed at each press station and are carefully lifted and positioned by a vacuum tool.

A large pneumatic press cylinder unit then presses the rivets through both the harness and membrane.

After the 2 riveting stations, the switches are then transferred to a fully automatic testing station, where the effort required to depress the switch is established in four different places.

The test information is recorded by a linked PC and each completed horn switch is identified by a barcode which is added using an inkjet printer at the offload position - as a second Sony robot removes the assembly from the index table and stacks it on a belt conveyor.

This information will be used by Pressac and its customers for long-term field diagnostics and statistical process control.

An interesting feature of the machine is that the 2 robots are second-hand units reclaimed from a redundant machine, demonstrating the long-term versatility and cost-effectiveness of robot solutions.

For maximum flexibility, the system has been designed to manufacture and test three product variants at a cycle time of approximately 5 seconds with minimal changeover requirements.

Says Project Manager Ian Rowland: "We are applying new riveting and testing processes to this machine which has already proved to be extremely accurate and can handle large components at high manufacturing levels.

It follows four similar projects for Pressac over the years but I think this will be our best machine yet in terms of productivity, accuracy and reliability.".

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