RōBEX Case Studies: Assembly Lines

Browse through three real-world examples of how RōBEX helped businesses overcome assembly (line) automation issues.

Automatic and Semi-Manual Assembly Systems
and Visual Inspection

RōBEX works with businesses of all sizes to find the most effective way to streamline processes and increase productivity. Read through the case studies below for more details about our approach to automation, inspection, and systems integration. Learn how RōBEX can help you optimize your assembly (line) automation!

Diesel Fuel Injector Assembly Line
Fully Automatic Balance Shaft Assembly System
Lift Gate Assembly & Visual Inspection

Diesel Fuel Injector Assembly Line

Diesel Fuel Injector

This system consists of six (6) main cells and one conveyor system transferring the customer’s assembly pallets from cell to cell. Each cell utilizes a robot for automatic part handling and handles a different aspect of the part’s assembly. Assembly parts are either introduced through the cell from a bowl feeder, or from pallets onto the incoming gravity conveyors. To address traceability, a part’s barcode is read at the start and at the end of the automatic process. Finally, the system is connected to the customer’s factory information and integrated throughout to provide comprehensive data about the process.

Super tight tolerances as low as 2 microns requiring 100% inspection after each assembly process.
The manufactured components required a method of data acquisition and part traceability.
The manufacturing process was too labor intensive for material handling.
The manufactured components required measurement inspections for validation of assembly.

1. Cell 1

Incoming Vision Inspection
Spring Vision Inspection
Spring Contact Probe Gage
Spring Assembly

2. Cell 2

Body Vision Inspection
Body Assembly

3. Cell 3

Body Contact Probe Gage
VOP Contact Probe Gage
VOP Assembly

4. Cell 4

Pin Contact Probe Gage

5. Cell 5

Pin Assembly
Orientation Vision Inspection

6. Cell 6

Laser Marking
Part Packout

AMC Flexlink Conveyor
Gravity Roller Conveyors
Powered Zone Conveyors
Adept SCARA Robotics
Custom EOATs with Pneumatic Gripper
Custom EOATs with Suction Cup
Cognex Vision Inspection
Solartron LVDT Probes
Telesis Fiber Laser Marker
Custom Bowl Feeders
Safety Interlocks
RTGC32 Controls Structure

Overview

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Design Gallery

Fully Automatic Balance Shaft Assembly System

Balance Shaft

This system consists of a complete automatic assembly of a balance shaft. Through a multistage assembly process, washers, gears, sprockets, bearings, and other various components are assembled onto the balance shaft. Balance shafts are then loaded onto an exit conveyor completely assembled and ready for installation.

Cycle time and production demand was too high for a manual process.
The assembly process was too labor intensive for material handling.
Multiple high-force presses were required.
Multiple torque operations were required.
Multiple subcomponents needed to be bulk fed into the system to allow for hours of unmanned production.

Washer Assembly Station
Input Gear Assembly Station
Sprocket Assembly station
Torque Station
Torque Inspection Station
Pin Assembly Station
Pin Assembly Station
Bearing Assembly Station

Powered Conveyor
Stelron Indexer
Fanuc Robotics
Custom EOAT
FEC Servo Press
FEC Torque Drivers
Futek Torque Sensor
Allen Bradley Servo Motors
Feeding Concepts Bowl Feeders
IAI Servo Drive
Cognex Vision Inspection
Safety Interlocks
Allen Bradley Controls Structure

Overview

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Design Gallery

Lift Gate Assembly & Visual Inspection

Lift Gate

This is an automatic torque, riv-nut, and inspection system with an inline manual process seamlessly integrated. Parts arrive at the cell via a powered belt conveyor. Robotics maintain part handling within the cell. Between the manual and automatic stations, various torque and assembly processes occur. Next, parts are transported to a vision inspection system to validate their assembly and Class A surface conditions. Parts are then sorted as either “good” or “reject” before leaving the cell.