Assembly
Assembly automation is highly customer and application specific. Requirements, components, joining and testing procedures are hardly comparable. This reflects the major challenge, which INSYS masters based on 20 years of experience in automation.
Characteristic in assembly automation are multiple feeding systems for a broad spectrum of components. In some cases, they are pre-processed in the feeding systems, while other applications include all processing on the main system.
Assembly combines a big variety of individual processes. Beside of standard pick-and-place, mechanical operations like punching, bending, screwing and riveting, soldering and welding (ultrasonic and laser) as well as optical and non-optical inspection are typical. In addition, applying protection foils, marking, labeling and packaging are representative. Intelligent, sensor controlled joining processes are a core element as well.
The reliable and realistic simulation of the whole process chain is a crucial point in the concept and quoatation phase. It determines the system performance and decides on the economical profit achievable. For this reason, INSYS applies its own simulation tools. Process parallelisation. e.g. by using multiple tooling and workpiece carriers, is a key factor to increase system performance. The flexible combination of round indexing tables, linear cells and robots does support the same strategy to define the most profitable concept .
Simulation and concept design
Choosing the right concept is the key issue! It is the key to maximum system performance, process control and economical profit. All our design engineers have been in automation for many years and bring into action all their knowledge. Concept design is a heavy pre-investment of INSYS in the quoting phase.
Parallelisation of processes
Workpiece carriers and processing stations are multiplied in order to ensure parallel processing of several units. Parallelisation is the most important measure for high volume throughput in automation.
Feeding a wide range of components
Continuous, smooth, oriented and sequential feeding of different parts is a main condition for successful automation. Standard feeding starts with bulk goods and vibrating feeders or shakers. Some applications start with palletized parts.
Robot supported assembly
Robot mounting of buttons for plastic foil keyboards, using a high speed Scara robot. Feeding of buttons is done by a vibrating feeder. Position and orientation of each button is detected by a vision system and pick-data are transfered to the robot. Process cycle time is below 2 sec.
Integration of third party modules
Due to the broad range of individual processes, integration of third party systems is frequently necessary. Main issues are the different cycle times of these systems and their individual software integration.
Linked systems
Complex assembly processes request the linking of several round indexing tables or linear cells. Sufficient buffering between the different systems is a key item for the performance and availability of the joint system.
All-electric handling (Pick and Place)
The substitution of pneumatic handling units by electric ones has significant advantages. Process modifications are achieved by pure changes of software parameters. Thus, electric handlings have a clearly superior flexibility in operation. The absence of compressed air consumption significantly lowers production costs.