Automation System Assembles, Tests Cylindrical Metal Parts
Vibratory bowls feed the components into the system.
Photo courtesy Prime Test Automation
The system consists of two halves: one assembles the parts, the other tests and marks the assemblies.
Photo courtesy Prime Test Automation
Two six-axis robots handle pick-and-place duties in the assembly cell.
Photo courtesy Prime Test Automation
Two SCARA robots handle pick-and-place duties in the test cell.
Photo courtesy Prime Test Automation
High on the list of challenges was the cycle time requirement: 4.5 seconds per assembly.
Photo courtesy Prime Test Automation
Every automated assembly system poses unique challenges for the engineers designing it. In some cases, it’s the small size of the parts or a tricky part orientation. In other cases, it’s the volume requirement or an unproven assembly process.
A recent system designed and built by Prime Test Automation posed two, seemingly opposing challenges: a fast cycle time requirement and a tight fit between the parts. The customer needed to join two drawn metal cans. The process requires an adhesive application, press-fit assembly, thermal testing, and laser marking.
High on the list of challenges was the cycle time requirement: 4.5 seconds per assembly. If that wasn’t enough of a challenge, the parts being assembled have a tight fit, increasing the overall precision required for the system. In addition, the adhesive had to be dispensed in an awkward geometry, eliminating some of the simpler design options for the project. Lastly, each assembly required a thermal test to ensure quality. Getting that done within the prescribed time limit forced even more creative solutions.
The automated assembly process features several creative, high-precision designs. It begins with vibratory bowls, which feed the components into the system. This allows the system to adapt to variable part orientations despite the complex geometries.
In the first half of the system, a rotary indexer transfers assemblies from station to station. Six-axis robots pick and place the components to ensure they are properly aligned for the adhesive dispensing system. Accurate alignment is crucial to the assembly process. Between applications, the indexer is moved to prepare the next component in line.
After the adhesive is dispensed, the two cans are joined. The assembly is assisted by forming stations that consistently create a tight fit for the parts. Two six-axis robots complete the joining process of the components.
The assemblies are then placed on a pallet. This pallet is on a conveyor that takes the assemblies in and out of the automated testing and marking stations.
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In this half of the system, a pair of SCARA robots transfer the assemblies from the pallets to the testing and marking equipment. Thermal testing is necessary to ensure that the assemblies can operate within specifications. Whenever an assembly passes the thermal test, it is laser-marked as a good product. From there, it is returned to the conveyor. The laser also engraves a serial number on each assembly for tracking purposes.
Despite the many steps in the automation process, assembly takes just under 4.5 seconds for each item.
For more information on automated assembly systems, click www.primetest.com or visit the company’s booth at The ASSEMBLY Show South, which will be held April 16-17, 2025, at the Music City Center in Nashville, TN.
Prime Test is one of several systems integrators exhibiting at the event. Others include the Arthur G. Russell Co., Edgewater Automation and Haumiller Engineering. You’ll also multiple suppliers of rotary indexing tables, linear transfer systems, and semiautomatic assembly cells.
Besides assembly machines, you’ll find some 150 suppliers of adhesives, fastening tools, robotics, parts feeders, presses, test and inspection devices, and other assembly technologies. The show is being held in conjunction with The Quality Show South and Adhesives in Action. For more information, visit www.assemblyshowsouth.com.
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