Location: Mexico
Project Value: $175,000 CDN for machine shown, $1.5 mil. CDN for complete line.
Turnaround Time: 34 Weeks for complete line

This automated assembly machine is one machine in a manual assembly line consisting of this dial station and (8) other machine bases with a total of (17) work stations.  It was designed and built for a customer in the automotive industry for their assembly plant located in Mexico and is employed in the assembly of seat belt retractor mechanisms.  Since this cell assembles a small explosive charge into a cartridge meant to lock the retractor in the event of a vehicle accident, all of these operations require a high degree of precision and attention to forces generated as well as assembly and manufacturing tolerances.  This station has a footprint of 1.5m wide x 1.6m long and the entire line requires floor space of 8.2m wide x 14m long.  It uses a Camco 6-Station rotary indexer, Baltec riveter, Keyence hi-definition vision components and linear probes for inspection, and is controlled with an Omron PLC thru an Omron HMI.  SMC pneumatic components were used throughout.  An operator loads a retractor assembly, an explosive cartridge, and cap into Station 1 and initiates cycle. Keyence vision components ensure that the proper cap has been loaded and the assembly’s unique bar code is scanned into the SCADA system before the fixture indexes through (5) more stations.  In Station 2 linear probes will verify the height and planar dimensions of the cap prior to riveting. Station 3 lifts the floating nest fixture slightly to avoid stress on the indexer table while a Baltec riveter runs one of ten different programs, depending on the measurements from Station 1, to crimp down the cap retaining lip.  Station 4 vacuums any debris produced during the riveting stage and Station 5 uses Keyence linear probes to verify the final assembly height.  The fixture passes through an idle station at Station 6 before being presented to the operator again at Station 1 for unload.  Cycle time for this line is 14 seconds part to part and the project took 34 weeks from launch to delivery.  For additional information about this automated assembly project or to discuss your own automation needs, contact us directly at info@iatglobalmfg.com.

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