Assembly February 2012

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ASSEMBLY

FEBRUARY 2012

www.assemblymag.com

Servo-Driven Grippers pg 32 High-Mix Assembly Driving Small Screws Resistance Welding

34 40 44

ASSEMBLY FEBRUARY 2012

Vol. 55, No. 2

32

66

COVER STORY

34

32 Quick-Change Artists

Servo-driven grippers lend flexibility to automated assembly lines in the automotive industry and beyond.—Jesse Hayes

40 FEATURES

DEPARTMENTS

34 Maintaining Quality in a Build-to-Order Shop

Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

For custom server appliance assembler MBX Systems, new procedures have virtually eliminated workmanship defects.—Jill Bellak

40 Automation for Small Screws

Tiny fasteners present big problems for assemblers. —Austin Weber

44 Adaptive Control of Resistance Welding 46

A new technology could reduce, or even eliminate, the need for destructive and nondestructive testing of robotically welded joints.—Tom Taylor

The time is right for reshoring.—John Sprovieri

New & Noteworthy . . . . . . . . . . . . . . . . . . . 8 Automated IV leak test system eliminates visual inspections.—Austin Weber

Fastening Threads. . . . . . . . . . . . . . . . . . . 10 Getting with the program.—David Archer

Assembly Lines . . . . . . . . . . . . . . . . . . . . . 12 ‘Assembly Plant of the Year’ award call for nomimations. —Austin Weber

Assembly Plant of the Year . . . . . . . . . . . 23 Nominate your facility for our annual award.

Assembly in Action . . . . . . . . . . . . . . . . . . 24 3D printer prototypes complex, multimaterial products. —Jim Camillo

Product Reviews . . . . . . . . . . . . . . . . . . . . 47 In-depth profiles of the latest assembly technology.

Case Studies in Assembly . . . . . . . . . . . . 51 NEXT MONTH Assembling Tractors How to Implement 5S Get Proactive for Safety Lean Plant Layout

Read how our advertisers have helped their customers solve problems and improve processes.

Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Classified . . . . . . . . . . . . . . . . . . . . . . . . . . 82

57

Advertisers Index . . . . . . . . . . . . . . . . . . . . 83

Cover photo courtesy SCHUNK Inc.

Shipulski on Design . . . . . . . . . . . . . . . . . 84

2 ASSEMBLY / February 2012 www.assemblymag.com

Lean and supply chain sensitivity.—Mike Shipulski

. t r a P e h t o t g n i h T t s e s o l C e h T Grippers ators u t c A y r a t o R s Linear Slide es sori s e c c A t o b o R

for the inside story, go to:

www.closestthing.com 800-772-4865

w w w . s c h u n k . c o m

ASSEMBLY NLINE

ONLINE TABLE OF CONTENTS

FEBRUARY 2012

WWW.ASSEMBLYMAG.COM

We’ve Changed!

ASSEMBLY now has a bigger and better Web site. The totally redesigned site delivers more information in an easier-to-navigate platform for an enhanced online experience. Features include quicker navigation with fast access to articles, special reports, columns and blogs. In addition, there’s an advanced key word search function that allows engineers to find articles by date, author or issue. There’s also social media integration for relevant content sharing. The site includes Web-exclusives, slideshows and 10 years of archived articles. You’ll also find content organized by key words, such as adhesives, fastening and robotics.

Web Extras AVOID THESE MISTAKES WITH SMALL SCREWS Engineers make several common mistakes with assembly applications involving small screws. For instance, underestimating or overestimating failure torque can cause problems. The correct torque depends on the size and tolerances of the boss hole, length of engagement, and the materials being fastened.

ASSEMBLY

WEBINARS Watch webinars on-demand at anytime.

ASSEMBLY webinars are a FREE and convenient way to get educated and informed on the latest industry topics. CONNECT WITH ASSEMBLY

Web Blogs UPDATED REGULARLY

ASSEMBLY editors and industry experts share their views on the latest in assembly and manufacturing.

» COMMENT ON THE LATEST POSTINGS » UPDATED REGULARLY

BEHIND THE SCENES AT SIEMENS’ NEW TURBINE ASSEMBLY PLANT In November, Siemens Energy opened a new gas turbine assembly plant in Charlotte, NC. Editor in chief John Sprovieri takes you behind the scenes.

ASSEMBLY

RADIO

ASSEMBLY SHOWROOMS Visit ASSEMBLY’s virtual product showrooms to view leading supplier information, products and services online.

TV

ASSEMBLY

ASSEMBLY Radio provides audio interviews on the latest news and topics in assembly and manufacturing.

HERRMANN ULTRASONICS: ULTRASONIC WELDING Herrmann Ultrasonics offers myriad solutions for joining plastic parts.

NOW PLAYING!

SEALANT EQUIPMENT: INDUSTRIAL DISPENSING From gasketing to potting, see how the experts at Sealant Equipment have tackled a wide range of automated dispensing applications.

» When Would You Use 3D Vision Technology? » TRW Manager Talks About Assembling Air Bag Inflators


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Editorial

ASSEMBLY

The Time Is Right for Reshoring

L

ast September, Otis Elevator Co. announced that it was moving production from its factory in Nogales, Mexico, to a new, $40 million assembly plant in Florence, SC. The new facility will bring more than 360 new jobs to South Carolina. The move is good news for South Carolina— where the unemployment rate stood at 9.9 percent in November 2011—and, indeed, for the country as a whole. Otis is one of a growing number of manufacturers that have decided to bring production back to the United States from overseas. According to a report released last month by the White House, real business fixed investment has grown by 18 percent since the end of 2009. In the past two years, 334,000 manufacturing jobs have been created, while manufacturing production has increased by 5.7 percent on an annualized basis since its low in June 2009. That’s the fastest pace in a decade. While reshoring is laudable for its own sake, recent economic conditions have produced sound business reasons for bringing work back home, too. Freight costs and overseas labor rates are rising. And even the Chinese yuan is inching up in value, from $0.152 in January 2011 to $0.158 in January 2012. Seizing the moment, the Obama administration is trying to promote more insourcing of jobs by U.S. companies after decades of outsourcing to foreign countries. At a forum hosted by the White House last month, the Obama administration announced steps to encourage more factory construction in the United States and more investment here by foreign companies. “Today I am meeting with companies choosing to invest in the one country with the most productive workers, best universities, and most creative and innovative entrepreneurs in the world: the United States of America,” Obama said prior to the forum. “And I’m calling on those businesses that haven’t brought jobs back to take this opportunity to get the American people back to work.” During the forum, Obama said his administration would soon propose new tax provisions to reward companies that bring back jobs to the United States or make new investments here. At the same time, the administration would move to eliminate tax breaks for companies that ship jobs overseas. The White House noted that although many other countries solicit business investment at the national level, the United States traditionally has left that job to the states. The Obama administration is trying to change that. Last year, it launched a program called SelectUSA to work with states to promote business investment. In addition, the Commerce and State departments will launch a pilot program in 10 countries to encourage businesses there to invest more in the United States. We applaud the Obama administration for encouraging investment in domestic manufacturing, and we urge U.S. companies to carefully consider the total costs of offshoring when deciding where to make their products. The time is right for reshoring.

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For more information on Loctite brand industrial adhesives and sealants, visit www.useloctite.com or call 1.800.LOCTITE (562.8483). ®

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Leak Test System Eliminates Visual Inspections

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Light-Cure Conformal Coating Is Solvent-Free E-MAX 903-E is a solvent-free, light-cure conformal coating that is engineered to cure with UV and visible light using DYMAX Corp.’s LED curing equipment. A secondary moisture-cure mechanism provides ambient cure in shadowed areas. The coating also features high chemical resistance, low viscosity, and a tack-free cure immediately upon cooling after light exposure. It is available in 30 milliliter syringes, 1-liter bottles and 5-gallon cans. Ellsworth Adhesives 800-888-0698 www.ellsworth.com

In-Line 2D Optical Micrometer Is Fully Automated The TM-3000 2D optical micrometer can be used in fully automated high-speed, in-line or off-line measurement and inspection applications. It combines the functionality of a laser scan micrometer, machine vision system and optical comparator into a single device. The micrometer is available in three sensor head sizes, along with the ability to use two transmitter-receiver pairs simultaneously to provide unparalleled flexibility. Because the system works in two dimensions, it can measure up to 16 points within the measurement area. Keyence Corp. of America 888-539-3623 www.keyence.com

www.assemblymag.com February 2012 / ASSE M B LY 9

Fastening THREADS

Getting With the Program

P

rogrammable torque tools have become popular in recent years, due to quality initiatives. However, quality improvements don’t come as soon as a new tool is plugged in. Properly sized and maintained, the torque scatter of a good (though much less expensive) clutch tool will not be substantially different than a programmable tool, if the latter is simply programmed to run at the same free speed and shut off at the same torque as the “dumb” tool. You should only make the additional investment for the opportunity to improve joint quality. Many engineers don’t take full advantage of that opportunity and fail to maximize their investment or their product quality. While there ■ By David Archer are several reasons for this, one big culprit is President uncertainty as to how to determine the parameters for programming a good tightening strategy. Archetype Joint LLC I’ll address the most common situation: Orion, MI [email protected] Target torque has been established by product engineering and the plant engineer must develop the tightening strategy. We’ll also assume that the joint doesn’t have unusual characteristics or requirements, so the most widely used strategy of torque control with angle monitoring can apply. Factors such as equipment, rundown, tightening and process limits should be examined. Equipment. This factor is applicable for any tool that has the programming capability to implement it. Though not directly tied to programming, one requirement for effective tightening strategy development and process control is the ability to plot torque vs. angle traces. Note that plotting torque against time is not the equivalent, as changes in spindle speed affect the slope of the trace. This, in turn, suggests joint behavior that is not actually present. Simultaneously plotting both torque and spindle speed against angle is the ideal means for understanding joint behavior during tightening. Rundown. This step covers advancing Archetype Joint the fastener from the point of socket or bit specializes in joint engagement until shortly after clamp load is design, testing being generated. The primary question in this and validation. step is how fast the spindle should turn. If the Dave Archer can fastener is free-running (no resistance from be contacted thread-forming or a locking feature), maximum at darcher@ speed can be used if socket engagement can be archetypejoint.com maintained. 10 ASSEMBLY / February 2012 www.assemblymag.com

Thread interference may require reduced speed, particularly when the fastener or nut member is a material other than steel. This can be determined by comparative testing. Rundown, and sometimes tightening, is more consistent when all adapters are eliminated and the distance between the fastener and tool drive is minimized. Take advantage of soft-start capability when the fastener’s drive features are difficult to engage. Tightening. This step starts at completion of rundown and ends with tool shut-off at the program’s conclusion. In most cases, the transition to tightening involves reducing spindle speed. At what torque this transition should occur, how speed is reduced and to what value, are decisions that should be made after consideration of each joint. This knowledge is nearly impossible without access to torqueangle-speed traces. The tightening step should start after the joint components are fully aligned, indicated by the torque-angle trace’s slope. This slope is a measure of resistance, which is more useful to think of as joint stiffness. Stiffness increases as component contact area increases, and then stays constant until clamp load is great enough to yield components. How close the transition point should be to the start of this linear portion of the trace is largely a function of how much the spindle turns before target torque is reached and how speed will be reduced. Earlier transitions tend to reduce scatter at an increase in cycle time. However, in most cases, rotation is so short the time penalty is trivial. Another speed-related phenomenon that should be avoided is stick-slip, a condition where friction fluctuates, causing “noise” in the trace as torque oscillates up and down. Premature shut-off is often the result. Experimenting with changes in speed should be the first response. Both these conditions usually produce a squealing noise, which should also be a flag for investigation. Final tightening speed should be related to fastener diameter, as friction can be influenced by the relative velocity of mating surfaces. Common ranges for clamp load-critical joints are 40 to 80 rpm for M8 (5/16 inch) bolts down A to 10 to 20 rpm for M16 (5/8 inch) bolts.

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Assembly Lines

Inventions New facilities ‘Assembly Plant of the Year’ Award Call for Nominations

Philips Respironics’s New Kensington, PA, facility was the recipient of the 2011 Assembly Plant of the Year award.

DEERFIELD, IL—ASSEMBLY Magazine and The Boston Consulting Group Inc. are currently seeking nominations for the 2012 Assembly Plant of the Year award. The 9th annual award will recognize a manufacturing facility in the United States that has applied world-class processes to reduce production costs, increase productivity, shorten time to market or improve product quality. Entries will be judged by ASSEMBLY’s editorial staff and BCG’s operations practice on a broad range of operational performance measures and the use of manufacturing management tools. The winning facility will receive a crystal award and a commemorative banner. Previous recipients have been Philips Respironics, New Kensington, PA (2011); Eaton Corp., Lincoln, IL (2010); Batesville Casket Co., Manchester, TN (2009); IBM Corp., Poughkeepsie, NY (2008); Schneider Electric/Square D, Lexington, KY (2007); Lear Corp., Montgomery, AL (2006); Xerox Corp., Webster, NY (2005); and Paccar Inc./Kenworth Truck Co., Renton, WA (2004). Companies interested in applying for the 2012 Assembly Plant of the Year award can fill out the online form at www.assemblymag.com.There is no entry fee, and more than one plant may be nominated. The deadline for submissions is April 30. For more information, contact Austin Weber at [email protected] or 847-405-4013. 12 ASSEMBLY / February 2012 www.assemblymag.com

Mergers

MFG Tray Celebrates 60th Anniversary LINESVILLE, PA—MFG Tray, a manufacturer of fiberreinforced composite products, is celebrating its 60th anniversary this year. It was one of the first manufacturers of massproduced commercial products using polyester resins and fiberglass reinforcements. “Known originally as Toteline, MFG Tray’s products gained popularity and acceptance rapidly into a variety of applications due to the durability and performance offered by composite construction,” says John Thompson, general manager.

MFG Tray is celebrating its 60th anniversary this year.

“We would not have survived 60 years without striving daily to be the best,” adds Thompson. “Our teammates’ desire to serve the customer and to deliver the highest quality product has never been compromised for any reason. We are very grateful to the customers, distributors and the MFG Tray teammates that

have made our first 60 years a success. We look forward to the next 60.”

Sensors Help Optimize Assembly Time MAGDEBURG, Germany—Traditionally, manufacturing engineers have manually timed assembly procedures to improve ergonomics, reduce waste and increase productivity. But, that method is prone to error. A new system records times automatically and cuts costs for manufacturers. Engineers at the Fraunhofer Institute for Factory Operation and Automation IFF have developed a system that uses three matchbox-sized sensors integrated in a sleeve. It records hand and arm movements precisely. The device also measures the start and end of individual actions, such as reaching, grasping, setting up, joining, checking or releasing. The interlinked sensor modules are positioned on the upper and lower arm and the hand. Assemblers only have to put on the two sleeves. They fit snuggly and don’t impede the wearer. “Until now, every individual movement has usually been timed by someone with a stopwatch or with digital time boards manned by employees,” says Martin Woitag, research manager at the Fraunhofer IFF. “This approach is not really objective, however.

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Assembly Lines

Sensors integrated in a sleeve record hand and arm movements of assemblers.

It is replete with errors and disadvantageous for everyone involved. The stress factor for employees is extremely high and they might not execute their jobs at their usual speed. “The stopwatch method only allows a process organizer to time five individuals simultaneously, depending on the situation,” adds Woitag. “Our solution makes it possible to re-

cord time simultaneously, even at several workplaces, without requiring additional labor. The system’s greater precision and objectivity is crucial.” Woitag and his colleagues rely on inertial sensors for their solution. They measure the acceleration and angular velocities of arms and hands in the X, Y and Z axes. Unlike other motion tracking systems, such


as GPS, the inertial measurement system functions without any other infrastructure. The inertial sensors independently detect objects’ positions in space. “What is more, our solution doesn’t require complex calibration,” claims Woitag. “A tool that teaches in the measuring points directly at the assembly workplace one time is all that is needed.” A PC application completes the system. The software calculates and reconstructs the motion sequences based on the sensor data. It breaks processes down into motion segments and ascertains the related times. The sleeves are currently used only for assembly tasks performed while sitting at workstations. But Woitag and his colleagues intend to configure the system to also

analyze assembly operations performed while standing or moving around. They plan to use the sensors to detect posture and analyze workplace ergonomics.

Misumi Opens New Distribution Center SCHAUMBURG, IL—Misumi USA Inc. has opened a new Los Angeles Distribution Center. The 34,000-square-foot facility in Torrance is located near Los Angeles International Airport. In addition to warehouse space, the building includes office space to house the company’s technical support and insidesales professionals. “The grand opening of our Los Angeles Distribution Center marks a significant mile-

Assembly Lines

“In phase one of [our] expansion plan, the new distribution center will be largely devoted to cross-docking of products,” adds Kaneda. “Phase two, scheduled for the Misumi USA Inc. has opened a new distribution near future, will center in Los Angeles. stone as we continue to grow allow for stocking of compoour U.S. customer base,” says nents which comprise much of Yoshihiro Kaneda, general our next-day delivery program.” For more information, contact manager of factory automation at Misumi USA. “The MISUMI at 800-681-7475. new center will help reduce lead times and freight shipping costs and, by supplementing our centrally located distribu- BMW Invests in tion capabilities in the Chicago South Carolina area, it will allow us to con- Plant tinue to serve customers with the responsiveness and rapid SPARTANBURG, SC—The delivery times our customers BMW Group is expanding expect and rely on. capacity at its 18-year-old

assembly plant here. The Spartanburg were exported, company plans to invest $900 making the BMW Group the million in the facility over the largest automotive exporter to non-NAFTA countries. next three years. Since it opened in 1994, “This will create 300 new jobs by the end of this year,” the Spartanburg plant has unclaims says Frank-Peter Arndt, dergone four expansions and the member of the board of produced six different BMW management of BMW AG models. Employment has responsible for production. grown from 500 initially to “This will allow us to produce more than 7,000 today. The state-of-the-art plant 350,000 units in Spartanburg uses advanced production in the midterm.” Last year, the BMW processes that make vehicle plant produced 276,065 vehicles for more than 130 markets around the world, representing an increase of 73 percent over the previous year. More than 70 percent of the vehicles BMW is investing $900 million in its Spartanburg, produced in SC, assembly plant.

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Assembly Lines

production environmentallycompatible. Over the past five years, the plant has lowered its energy consumption by 48 percent, reduced CO2 emissions by 44 percent and waste by 65 percent. In 2010, the Spartanburg plant generated almost 62 million kilowatt hours of electricity from a methane gas energy center located on the grounds of the facility and supplied by a local landfill. This accounts for more than 37 percent of the entire plant’s total electrical demand.

Sysmelec and MTA Automation Merge GALS, Switzerland—Sysmelec SA and mta automation ag have merged their operations and created a new company called Unitechnologies SA. “Through the effect of size

and synergies, the new company will be able to significantly improve the services offered to [our] customers,” says Emilio Stornaiuolo, CEO. Under the Sysmelec and mta brand names, Unitechnologies will focus on its traditional markets, which include medical, watchmaking, automotive, microelectronic, electromechanical and optoelectronic applications. “In the future, new and innovative products destined for the automation of technological processes will be added to the range of current equipment,” says Stornaiuolo.

New Online Tool Aids Material Research CAMBRIDGE,

MA—The

Massachusetts Institute of Technology (MIT) and the Lawrence Berkeley National Laboratory have developed an online toolkit that allows engineers to easily find a material with specific properties. Using a Web site called the Materials Project, it’s now possible to explore an evergrowing database of more than 18,000 chemical compounds. The site’s tools can quickly predict how two compounds will react with one another, what that composite’s molecular structure will be, and how stable it would be at different temperatures and pressures. The project is a direct outgrowth of MIT’s Materials Genome Project, initiated in 2006 by Gerbrand Ceder, a professor of materials science and engineering. The idea, he says, is that the site “would become the Google of

material properties,” making available data previously scattered in many different places, most of them not even searchable. For example, it used to require months of work—consulting tables of data, performing calculations and carrying out precise lab tests—to create a single phase diagram showing when compounds incorporating several different elements would be solid, liquid or gas. “Now, such a diagram can be generated in a matter of minutes,” claims Ceder. “The new tool could revolutionize product development in fields from energy to electronics to biochemistry, much as search engines have transformed the ability to search for arcane bits of knowledge,” adds Steven Chu, U.S. secretary of energy. “It could drive discoveries that not only help power

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Assembly Lines

clean energy, but are also used in common consumer products. This accelerated process could potentially create new domestic industries.” According to Ceder, the Materials Project is much more than a database of known information. The tool computes many materials’ properties in real time, upon request, using the vast supercomputing capacity of the Lawrence Berkeley Lab. “We still don’t know most of the properties of most materials,” says Ceder, but in many cases, these can be derived from known formulas and principles. Already, more than 500 engineers from universities, research labs and manufacturers have used the new system to seek new materials for lithiumion batteries, photovoltaic cells and new lightweight alloys for use in cars, trucks and airplanes. Chu believes the development

of new materials for clean energy, transportation, electronics and other fields could be the key to revitalizing American manufacturing. “I don’t think we’re going to be manufacturing the old things,” he points out. “We have to be constantly innovating,” claims Chu. “If we could do more rapid materials development, we could push things out into manufacturing much faster.” For more information about the Materials Project, click http://materialsproject.org.

Spirol Honored for Green Initiative DANIELSON, CT— SPIROL International Corp., a leading manufacturer of fastening and joining components, was recently presented with the 2010 GreenCircle

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Award by the Connecticut Department of Energy and Environmental Protection for the creation of the SPIROL Nature Conservation area. This is the second time the Microneedles penetrate the upper layer of the company has been skin without reaching nerves. recognized for environmental preservation. developed a new silk-based SPIROL’s first GreenCircle microneedle system that Award was received in delivers precise amounts of 2008 for its Environmental drugs over time and without need for refrigeration. The Management System. tiny needles can be fabricated under normal temperature and so they can be loaded Silk Microneedles pressure, with sensitive biochemical Deliver Controlled- compounds and maintain their activity prior to use. They Release Drugs are also biodegradable and Painlessly biocompatible. While some drugs can be MEDFORD, MA—A team of researchers at Tufts University swallowed, others can’t surSchool of Engineering have vive the gastrointestinal tract.

Cut, strip, and terminate wires with the fully automatic %TKOR%GPVGT. Equipped with high precision technology, the %TKOR%GPVGT features a compact modular design offering space for up to 6 processing stations, such as seal loaders, twisting and tinning stations, doubling unit, etc. Dynamic and powerful servo motors combined with an intelligent control system provide high output rates to meet even the most demanding production schedules. Quick changeovers make it ideal for low volume, high-mix jobs as well as larger production runs. The %TKOR%GPVGT is the perfect passenger for your road trip to success.

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Innovators in Wire Processing 20 ASSEMBLY / February 2012 www.assemblymag.com

To Be Precise.

Assembly Lines

Hypodermic injections can be painful and don’t allow a slow release of medication. Only a limited number of small-molecule drugs can be transmitted through transdermal patches. Microneedles no more than a micron in size and able to penetrate the upper layer of the skin without reaching nerves are emerging as a painless new drug delivery mechanism. But, their development has been limited by constraints ranging from harsh manufacturing requirements that destroy sensitive biochemicals, to the inability to precisely control drug release or deliver sufficient drug volume, to problems with infections due to the small skin punctures. The process developed by the Tufts bioengineers addresses all those limitations. It involves ambient pressure

and temperature and aqueous processing. Aluminum microneedle molding masters were fabricated into needle arrays with a radius of less than 10 microns and a height of about 500 microns. Elastomer polydimethylsiloxane was cast over the master to create a negative mold; a drug-loaded silk protein solution was then cast over the mold. “Changing the structure of the secondary silk protein enables us to ‘preprogram’ the properties of the microneedles with great precision,” says David Kaplan, chairman of biomedical engineering at Tufts. “This is a very flexible technology that can be scaled up or down, shipped and stored without refrigeration and administered as easily as a patch or bandage. We believe the potential is enormous.”

Schunk Symposium to Feature Leading Experts MORRISVILLE, NC— Schunk Inc., a leading supplier of clamping technology and gripping systems, will host its 5th annual Expert Days on Service Robotics on Feb. 29 and March 1. Under the motto “Service Robotics—Quo vadis?” the forum will examine the opportunities and potentials of this rapidly growing market. Topics will include “Perception and Learning,” “Robots and Component Design” and “Robots and People.” Top-notch speakers from around the world will present current trends, the latest research and promising business models. Two of the honored guests will be Dr. Roland Siegwart

See us at ATX Texas, Booth 1505 22 ASSEMBLY / February 2012 www.assemblymag.com

Schunk will hold its 5th annual robotics symposium on Feb. 29 and March 1.

from ETH Zurich and Steve Cousins from Willow Garage, a firm that develops hardware and open-source software for personal robotics applications. For more information, click http://expertdays.schunk.com or call 800-772-4865.

Presented by and NO ENTRY FEE! We’re looking for plants that have applied world-class assembly processes to reduce production cost, increase productivity, shorten time to market or improve product quality. Any assembly plant in the United States is eligible. Plant size, type of assembly process or type of industry is not important, as long as the facility is involved in joining discrete parts into finished products. The 9th annual Assembly Plant of the Year award will be presented at a special ceremony at the winning plant. The plant will receive a commemorative banner and will be featured in the October issue of ASSEMBLY magazine. To nominate a plant, click www.assemblymag.com. For questions, contact [email protected]

Deadline April 30, 2012

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IBM CORP. Poughkeepsie, NY

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Assembly in Action

3D Printer Prototypes Complex, Multi-Material Parts

F

Jaguar Land Rover uses the Connex500 3D printer to develop and test prototypes of complex, multi-material parts. Photo courtesy Jaguar Land Rover

For reprints of any Assembly in Action article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516.

or more than a decade, the Coventry, UK-based wing of Indian TATA Group has owned Jaguar and Land Rover—two very different types of vehicles. Jaguar was launched in 1935 as the first affordable sports car capable of 100 mph. The Land Rover, first built in 1948, is an all-purpose vehicle with offroad capabilities. Currently, Jaguar Land Rover (JLR) produces eight vehicle lines. To ensure that these lines maintain their premium position in the marketplace, nearly 20 percent of JLR’s workforce is employed on product development. These workers use a variety of tools to quickly create and approve designs. These tools include CNC model making, a fully equipped metalwork and tool shop, and in-house prototyping. JLR uses several rapid prototyping machines, including a Connex500 3D printing system made by Objet Geometries Ltd. JLR chose the Connex500 because it features PolyMatrix technology, which allows fast development and testing of complex, multi-material parts directly from CAD data. By jetting two distinctive model materials in preset combinations in a matrix structure, the machine can create prototypes made of flexible and rigid materials, with different mechanical and physical properties, and various finishes. The system can print models made of up to 14 different materials in a single


print job. It prints ultrathin 16-micron layers and can create models up to 500 by 400 by 200 millimeters. The printer uses FullCure materials to create accurate, clean, smooth and highly detailed 3D parts. In 2008, the Connex500 was initially used to produce a complete facia air vent assembly, as a working part, for a Range Rover Sport. Rigid materials were used for the housing and air-deflection blades. Rubber-like materials were used for the control knobs and air seal.

The machine can create prototypes made of flexible and rigid materials. The assembly was produced in a single process. Once printed, the assembly was cleaned and tested immediately to make sure that all hinges on the blades worked and the control knob had the right look and feel. Since then, the system has accumulated 5,000 hours of operation, used 600 kilograms of resin, and printed more 2,500 parts. Although this amount represents a small percentage of the 30,000 parts prototyped annually by JLR, the number produced on the Connex500 has been steadily in-

Jaguar Land Rover used the Connex500 to create a headlamp washing system. Photo courtesy Migueldefender (YouTube)

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Assembly in Action

creasing. Currently, the printer produces more than one third of JLR’s resinbased part prototypes. The JLR styling department is the most frequent user of the system. More than half of everything produced on the 3D printer finds its way into the design studio to help finalize new design proposals.

A good example is the creation of an entire telescopic headlamp washing system that extends and cleans headlamps every fifth time the windscreen is washed. The Connex-printed components proved to be robust enough for rigorous testing, verifying their design before moving into the expensive tooling stage.

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JLR also uses the printer for overmolding. For example, two materials are used, but not mixed, to create a cover with a rubber seal. Once the seal is cleaned, it is used directly for fit and function testing. The company also uses the printer to develop door seals and protective gaiters made of its proprietary material TangoBlackPlus. This nonrigid material allows designers and manufacturers to create high-quality prototypes that closely resemble a broad range of rubber products. For more information on 3D printers, call 877-489-9449 or visit www.objet.com.

hreveport, LA, is home to an Android Industries assembly plant and a General Motors manufacturing plant. Located just 1 mile apart, the two companies work closely together. Every day, Android ships hundreds of engine and transmission assemblies to GM by trailer truck for just-in-time placement onto awaiting chassis for Chevy Colorado and GMC Canyon trucks. In fact, Android’s decision to build its plant in Shreveport was the result of being awarded a GM assembly contract to support the introduction of these two truck lines. Opened in 2003, the Android plant encompasses 226,000 square feet. Interestingly, not one robot can be found in all that space. Instead, located up and down the assembly line are skilled

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Flow Cell workstations allow workers to quickly and easily grab components for assembly. Photo courtesy UNEX Manufacturing Inc.

Over 25 years I have attended or exhibited at trade shows in many sectors around the world. I never thought that there could be a virtual equivalent to a physical show until Tech ManufactureXPO. I made a good number of contacts and had some very interesting discussions. The content, quality of exhibitors and the mechanics of navigating the show were excellent. It was well worth my time. Congratulations on an innovative event! - D.Paul Zito,, W.E.S.T. Forwardingg Services

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Assembly in Action

technicians accompanied by modular Flow Cell workstations that help them meet and exceed critical production targets. Shreveport is the first Android Industries facility to use Flow Cell workstations, says Mark Geer, lead engineer for Android and a member of the facility’s launch team. From these workstations,

which are made by UNEX Manufacturing Inc., workers quickly and easily grab components that they then attach to engine and transmission assemblies at a steady pace. “We can put four days worth of material on the Flow Cell and not have to replace material,” says Geer. Geer outfitted the Shreveport plant

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with equipment similar to that used in the company’s other plants. However, when it came to workstations, he wanted an alternative to pipe-type structures with plastic wheels—which the company had used in other plants. Flow Cell workstations feature standard mix and match components that include vertical posts, horizontal beams, and Span-Track full-width roller tracks. The components are durable and designed to withstand the heavyduty high-volume pace of manufacturing plants. They are made to perform well for many years and come with a seven-year warranty. Geer likes that the components create a workstation that is durable, mobile and ergonomic. He also likes the system’s flexibility. Workstations can be assembled, disassembled and reassembled quickly and easily as needed. Common reasons include a new worker who needs the workstation to be a different height, or the workstation must be moved to a different area of the plant. Geer also likes the Span-Track roller tracks, which allow easy component flow from load point to pick point and are easy to reposition in the workstation. Android workers use the tracks to transport items like bolt boxes and hand-to-handle totes. The Shreveport facility features 22 Flow Cell workstations, which were all constructed in one day by production line employees. Geer says each one took about 30 minutes to build. For more information on modular workstations, call 888-460-7726 or visit www.unex.com.

LED Lighting Brightens Floor, Finances at Metal Parts Plant

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panish manufacturer Martisa produces metal parts for the automotive industry at its Barcelona plant. However, the plant, which measures 1,288 square meters, has experienced various lighting problems the past several years.

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Assembly in Action

DuroSite lights provide consistent luminance of 200 lux at floor level. Photo courtesy Dialight Corp.

The facility’s 32 400-watt high-pressure sodium (HPS) lights often flickered and dimmed due to energy surges caused by the plant’s metal processing machinery. The HPS lights produced inconsistent lighting throughout the plant; illuminance varied from 118 to 270 lux at floor level. Also, the lights took 10 minutes to re-strike following power outages, negatively impacting productivity. Maintenance was also a challenge, as the HPS lights were mounted at a height of 9 meters, ran 10 hours a day

five days a week, and had to be replaced every 10,000 hours. Each replacement light cost 50 euro, while the mobile elevation platform required to install the light cost 100 euro per day. Looking to create better and more even lighting—as well as save energy—company executives met with energy consultant Area Energetica, which is a partner of lighting distributor Inelec. Area Energetica recommended replacing the HPS lights with DuroSite LED High Bay lights made by Dialight Corp. DuroSite LED High Bays are 150watt lights that are L7 rated to last 80,000 hours and maintain 80 percent luminance after 60,000 hours. The lights produce minimal heat with no ultraviolet light or infrared radiation. They also require no maintenance, come with a 5-year continuous performance warranty and are mercury-free.


DuroSite lights are mounted at the same height as the HPS lights, but they provide consistent luminescence of 200 lux at floor level. Martinez says DuroSite lights also switch on and off instantly to improve lighting efficiency and reduce re-strike time following power outages. The new lights have reduced Martisa’s lighting energy use by 69 percent, from 9.9 watts per square meter to 3.7 watts. The lights have also reduced the plant’s carbon emissions. Each fixture weighs 17 pounds and features a housing made of copper-free, powder-coated aluminium. IP6-rated, the housing is designed to withstand dust and moisture. The fixture can be equipped with an acrylic, polycarbonate or tempered flat lens, or a polycarbonate dome lens. For more information on LED lights, call 732-919-3119 or visit www.dialight.com.

Assembly in Action

Supplier Improves Welding Quality With 3D Vision

K

WD Automobiltechnik GmbH manufactures side panels and assemblies for various car manufacturers at its Wolfsburg, Germany, plant. There, KWD has a welding station that uses 3D image processing software to improve robot guidance and welding quality. The station features three KUKA robots: one for spot welding and two for handling the parts. The parts-handling robots are equipped with grippers and integrated vision systems. KWD uses Cognex VisionPro 3D image processing software in conjunction with the vision systems. As welding begins, one robot is positioned in front of the component magazine. Inside the magazine, arranged horizontally in a stack, are small parts to be welded to the side panel. The robot verifies the correct position of the parts and grabs them, whereupon pins

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secure a side panel in place. Meanwhile, a second robot with a twosided gripping system positions itself in front of the transport rack that contains large parts arranged in a vertical stack. This robot checks the position of the transport lock, measures the position of the large parts, and picks them up. Subsequently, both robots move to the loading station and put down the parts in the correct position and in the logical sequence. Welding is then performed by a spot welding robot. Afterward, vision systems in the first and second robots check the number and location of the welds, and whether they were placed in the predefined fields. The vision systems also examine whether the roots of the weld points are correct based on the parameters of the welding control. Data obtained from the testing is archived, and images are assigned to the associated parameters. In this way, KWD achieves complete traceability

On Time On Budget On Purpose

At KWD’s assembly plant in Wolfsburg, Germany, 3D image processing software improves robot guidance and welding quality. Photo courtesy Cognex Corp.

and documents and verifies quality. Each welded component is then removed by the second robot and placed in the transport rack for finished parts. Once the required number of finished parts is stacked in the rack, a signal is sent to transport logistics, which collects the full rack and delivers a new empty rack. The process is then repeated. For more information on 3D vision software, call 508-650-3000 or visit www.cognex.com.

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www.xasinc.com www.assemblymag.com February 2012 / ASSE M B LY 31

ASSEMBLY

Robotics

Quick-Change Artists Servo-driven grippers lend flexibility to automated assembly lines in the automotive industry and beyond.

As model variety increases, automotive components can only be produced profitably if automated assembly lines can be changed over in a short time. Photo courtesy FANUC Robotics

For information on how to obtain reprints/e-prints of this article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516. By Jesse Hayes Automation Product Manager SCHUNK Inc. Morrisville, NC

T

he major advantage of robots is their flexibility. It’s ironic, then, that robot end-effectors are typically custom-made for a specific part. If the robot must handle different parts in the same run, a tool changer and multiple grippers are often required. However, pausing to swap grippers is unproductive, and storing multiple sets of grippers on the line takes up valuable floor space. This issue is particularly acute in the automotive industry, where more and more OEMs and suppliers are moving towards universal plants and flexible assembly lines. As model variety increases, engines and other components can only be produced profitably if automated assembly lines can be changed over in a short time. Multifunctional servo-driven grippers, which can handle a variety of parts in alternating succession, are one solution to the problem. For example, flexible servo-driven grippers are available for handling crankshafts, cylinder heads or motor blocks. A special gripper equipped with a compensation unit can handle four types of cylinder heads weighing up to 95 kilograms. The compensation unit rests on a floating bearing and is then locked eccentrically. A stroke of 342 millimeters enables the gripper to pick up components of different sizes. The compact gripper integrates with the existing robot controller and does not require an additional control unit or regulator. Flexible grippers for automotive welding lines are more complex. For reliable handling, numerous factors have to be considered, such as the


variety of part sizes; the varying surfaces and positions of gripping points; and the forces and vibrations affecting the gripper. Ideally, the parts and assembly line should be designed at the same time. For example, when designing parts, engineers should try to identify identical clamping and gripping points.

Thanks to plug-and-play connectivity, the gripper works like another robot axis. Lightweight Grippers A robotic cell for automotive side sills provides an idea of what a flexible clamping and gripping system for vehicle assembly might look like. The cell was jointly developed by SCHUNK, FANUC Robotics and systems integrator FFT EDAG. The cell consists of one six-axis robot for assembly and an additional six-axis robot that acts as a flexible clamping device. The latter is equipped with a SCHUNK LEG long-stroke electric gripper. The standardized, modular gripper weighs 8.8 kilograms, grips with a maximum force of 1,140 newtons, and provides a stroke length from 0 and 568 millimeters. For this application, it was equipped with a servo-electric drive from FANUC. Thanks to plug-and-play connectivity, the gripper works like another robot axis and can be actuated with the same instruction set. Two degrees of freedom at the gripper, five at the device, and six at

Made from carbon-fiber composite, this gripper weighs just 10 kilograms. Photo courtesy SCHUNK Inc.

the robot open up a new spectrum of possibilities for assembly. To save more weight in end-of-arm tooling, grippers can be made from composites. For example, SCHUNK offers a long-stroke gripper, the LEG-C, made of a carbon-fiber composite with a scalable pneumatic drive. At a weight of 10 kilograms, the LEG-C provides a maximum gripping force of 4,000 newtons and a variable stroke of up to 600 millimeters. If shortened finger travels are required, the stroke can be individually scaled. This minimizes cycle times and reduces compressed-air consumption, which makes the gripper much more

The SDH-2 three-finger gripper was designed to mimic the ability of the human hand. Photo courtesy SCHUNK Inc.

Pausing to swap grippers is unproductive, and storing multiple sets of grippers on the line takes up valuable floor space. Servo-driven grippers solve that problem. Photo courtesy SCHUNK Inc.

efficient. The gripper’s aluminum fingers are also executed in a lightweight design. They travel on recirculating ball-bearing carriages. The gripper can be exactly adjusted to the individual payload. In case of particularly high gripping forces or extremely long fingers, the distance between the carriages can be enlarged. This way, even fingers with a length of more than 1,000 millimeters can be used. The belt drive and the synchronized fingers ensure that the gripper works precisely at variable strokes. This is ideal when large and small parts have to be alternately handled. In addition to flexibility, lightweight servo-driven grippers are also more energy-efficient. Gripper Lends a Hand For gripping a wide variety of small components, the human hand is surely the best template. The SDH-2 three-finger gripper was designed to mimic the ability of the human hand. With its seven independent degrees of freedom, it can grip and position various objects without any setup. A tactile sensor system safely and sensitively monitors the optimum grip and supplies information to the control unit to make gripping corrections if necessary. This enables even difficult geometries to be reliably handled, positioned and inserted. The gripper is also protected

against dust and humidity. In the future, the automotive industry will have highly flexible manufacturing plants that do not need rigidly defined tools, devices or grippers. Sensorequipped, servo-driven gripping and handling systems will be the linchpin of these new plants. A

ASSEMBLY ONLINE For more information on robotic assembly, visit www.assemblymag.com to read these articles: Assembly Showroom: SCHUNK Inc. Assembly in Action: Automated Feed System Heats Up Production of Cold-Forming Press. Assembly in Action: Waterproofing a Space Robot.

Servo-driven grippers allow alternate handling of engine blocks, wheel rims, crankshafts and cylinder heads. Photo courtesy SCHUNK Inc.


ASSEMBLY

Flexible Assembly

Maintaining Quality in a Build-to-Order Shop For custom server appliance assembler MBX Systems, new procedures have virtually eliminated workmanship defects.

Instead of using printed tickets and manually crossing items off the list as they are picked, technicians now use iPads mounted on carts in conjunction with Bluetooth bar code scanners. Photo courtesy MBX Systems

For information on how to obtain reprints/e-prints of this article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516. By Jill Bellak Chief Operating Officer MBX Systems Wauconda, IL [email protected]

I

magine assembling Samsung, Sony, Sharp and Toshiba televisions in the same plant at the same time— each with different flat panels, components and features, from built-in WiFi to 3D displays—and you’ll have some idea of the challenges facing MBX Systems in manufacturing made-to-order server appliances and embedded systems. Each custom-built appliance uses a different chassis, dozens of different components, and variations in processes such as cabling, branding, software image loading, and testing. These widely divergent requirements can wreak havoc on scheduling, workload distribution, on-time delivery and particularly quality control. Several years ago, MBX addressed these issues by developing special production, picking, tracking, staffing and quality control procedures. The company also developed proprietary shop floor software tailored to the plant’s needs. Highlights include a new work center arrangement with more narrowly defined tasks, replacement of written build instructions with visual documents to facilitate correct assembly of each system, and deployment of Apple iPads to replace a picking system based on paper tickets. Over the next year, these and other changes yielded: A 42 percent reduction in system and workmanship defects. A 57 percent increase in manufacturing volume in the same physical space. A 94 percent customer retention rate, up from 77 percent.


A 116 percent jump in sales, even

during the depths of the recession. Significantly, much of that growth came from new customers dissatisfied with their previous contract manufacturers. One such customer was a digital media services company whose appliances frequently malfunctioned within hours of deployment. Another was a provider of investigation management software whose previous supplier shipped three defective boxes in a row. Those reliability problems disappeared with the switch to MBX, thanks to the strategies the plant established for maintaining quality in a high-mix environment. Hundreds of Permutations MBX primarily manufactures OEM hardware appliances used by software vendors as an alternative to delivering their applications to corporate data centers on CDs, as electronic downloads or in the cloud. Each system is built to optimize the performance of that particular application and preloaded with the vendor’s software, eliminating the need for IT staff at the customer site to install, configure and fine-tune software setup. Applications include data archiving, network storage, network monitoring, data and network security, content management, voice over IP, video production and video on demand. MBX also manufactures turnkey hardware-and-software modules to be embedded in products ranging from medical equipment to industrial machinery. With these disparate functions and unique customer needs, no two platforms are alike. One system may

be the size of a set-top box, while another may occupy a 6-foot-tall rack large enough to hold 42 servers. Some will have video capture or TV tuner cards, while others will require encryption chips, solid-state hard drives or other specialty parts in addition to motherboards, processors and memory to match the specific application. Customers such as SnapStream, a supplier of television search and monitoring appliances, have unique requirements, such as custom testing and special configuration of each machine based on the channels the end user wants to record. Other needs such as custom scripting, special back-ofmachine port labeling, specialty brackets to hold components in place, and antitampering features for government use, add to the challenge of consistently delivering quality product. Yet MBX is succeeding. “Since all of our customers require 24/7 reliability, it’s mission-critical that we provide the [best performing], fault-tolerant and efficient serverclass hardware. MBX not only helps us accomplish that feat, but also goes the extra mile to ensure the future success of our company,” says Adrienne Gonzalez, enterprise support specialist at SnapStream, which has reported only two defects since MBX began implementing its new manufacturing software and processes in 2009. Divide and Conquer As part of those operational changes, MBX divided the assembly process into more discrete tasks, doubled the number of work centers to correspond to those tasks, and imposed associated controls, such as automatically displaying build instructions on the assembler’s computer monitor as a job arrives at his workstation. Instead of the previous threestation setup, MBX now runs six work centers. Each job begins with picking in the warehouse and then moves to preassembly, where raw components like motherboards and hard drives are installed into the chassis.

In one year, MBX reduced system and workmanship defects by 42 percent. Photo courtesy MBX Systems

Next comes: which includes wiring and installation of custom-branded faceplates, color-coding of ports for easy customer connectivity, and in some cases the addition of security protections, such as blocking unused ports. Visual inspection, to validate the accuracy of the physical assembly. Configuration, for software installation and testing. Final quality control inspection, to approve the physical appearance and functionality of the finished appliance. Supporting this new arrangement Cabling,

is MBX’s new project management software, called Signal, and an array of other new processes specifically designed to cope with the variation in customer needs. These include: Customized workflow for each appliance. When each new job order comes in, platform engineers work with the customer to determine his needs, configure the system, create the bill of materials, and define the steps required to complete the build. The workflow is then entered into the production software, which makes it possible to customize job routing for each order

MBX divided the assembly process into more discrete tasks, doubled the number of work centers, and imposed controls, such as automatically displaying build instructions on the assembler’s computer monitor. Photo courtesy MBX Systems www.assemblymag.com February 2012 / ASSE M B LY 35

Flexible Assembly

When each new job order comes in, engineers work with the customer to determine his needs, configure the system, create the bill of materials, and define the steps to complete the build. Photo courtesy MBX Systems

based on the tasks that must occur in each work center and the background processes required to fulfill these tasks. Wiki-based documentation of each platform design. Use of a wiki instead of printed design documents ensures that assemblers have access to current build information on every appliance

or embedded system. Design updates based on component changes or work center feedback to manufacturing engineers can be incorporated into the wiki immediately and tracked by date, user and reason for future reference. Replacement of text-based assembly instructions with visual documentation.


As prototypes are being assembled, documentation technicians develop visual build documents that show every component location, cable turn, screw torque and other information. These documents, with accompanying written instructions, are entered into the wiki and displayed at the relevant work center on professional-grade 23-inch LCD monitors with a wide, 178-degree viewing angle that enables assemblers to view the screen from multiple positions without distortion. Build instructions customized for each work center. As each hardware unit arrives at a workstation, the builder scans a bar code affixed to the chassis and instantly receives build instructions related exclusively to the tasks for which that station is responsible. Removing instructions that are not relevant to a particular work center saves time and eliminates confusion. Quality Plus Efficiency All of MBX’s processes contribute to quality assurance. For example, adding

As prototypes are being assembled, documentation technicians develop visual build documents that show every component location, cable turn, screw torque level and other information. Photo courtesy MBX Systems

a new inspection work center midway through the line process enables assembly errors to be caught earlier in the build. In fact, every appliance or embedded system undergoes repeated inspections—not just one unit in 10 or 50. Numerous other checkpoints and controls also help keep workmanship defects at bay. For starters, assemblers at each work

A defect review team meets regularly to examine the most frequent build defects and develop strategies to minimize errors. Photo courtesy MBX Systems

center physically check the previous station’s accuracy against the visual build document to see if there is any deviation. As a result, every appliance is inspected at least five times—once for each work center after leaving preassembly. Any anomalies are recorded and corrected by the builder before the order moves to the next workstation. Second, if any configuration step is overlooked, MBX’s production

software automatically detects the omission, posts a warning on the computer screen, and prevents the builder from signing out and passing the mistake to the next work center. That safeguard prevents configuration errors, such as delivering an appliance loaded with the wrong software version or neglecting to capture a MAC address required to identify the device on the customer’s network.

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Flexible Assembly

Each custom-built appliance platform uses a different chassis, dozens of different components, and variations in processes such as cabling, branding, software image loading, and testing. Photo courtesy MBX Systems

Third, MBX has a defect review team consisting of the director of manufacturing, a diagnostics specialist, and quality control and configuration technicians. The team meets regularly to examine the most frequent build defects and develop strategies to minimize human

“D4”

error. Based on their findings, the team may then modify build documents to clarify assembly processes. The team’s recommendations have helped drive continuous improvement and reduce defects, particularly on new platforms where errors are most likely to occur.

None of these quality control measures have diminished manufacturing efficiency, largely due to the ability of MBX’s production software to facilitate scheduling, workload distribution and adherence to customer deadlines. With the Signal software, schedules are optimized by analyzing booked vs. actual work time, employee calendars and time clock data. Managers can easily spot developing bottlenecks and move assemblers between work centers to keep operations running smoothly. Up to 15 people can work on the same order simultaneously to maximize output. Orders can be reprioritized on the fly to accommodate rush jobs or other scenarios. In addition, the software has given managers better insight into job costing and enabled real-time productivity metrics to be displayed on large monitors on the shop floor so assemblers can easily monitor their progress against estimated build times. This helps keep production moving.

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Picking With iPads By changing the way raw materials are picked and staged from the warehouse, engineers have cut order picking time by 30 percent, reduced picking errors by 20 percent, increased orders picked by 14 percent every month, and even expanded MBX’s manufacturing footprint. Instead of using printed tickets and manually crossing items off the list as they are picked, MBX now uses iPads mounted on carts in conjunction with Bluetooth bar code scanners. The ticket for a given order is served up to the iPad. Each item is scanned into the tablet as it is picked, and the plant’s production software automatically flags picking mistakes in real time so they can be corrected before assembly begins. In the past, technicians would print 40 or 50 tickets simultaneously and pick them as time allowed, regardless of when a given build will begin. Now, a kanban process is used to link order picking and cart staging to the production schedule. The software prioritizes

orders and displays the next job in the queue as space opens in the staging area, where picking carts are numbered and parked in the corresponding spot. These techniques have eliminated premature picking that required surplus staging space, allowed that space to be reallocated to production, and avoided time wasted in searching for the cart with the appropriate pick ticket. Bottom Line With these systems in place, MBX has been able to both attract and retain an A list of clients ranging from specialty software providers to Fortune 500 companies. Also contributing to brisk business are the facility’s ISO:9001 2008 certification and value-added services, such as design; sourcing and stocking of branded faceplates for each customer; engineering assistance; component life cycle management, which helps keep hardware platforms current; and global logistics for stocking finished systems in warehouses worldwide for

fast on-demand local delivery. Another plus is an online customer portal that provides real-time data on each customer’s order history, order status, appliance specifications, inventory, shipment, pricing and returns. None of these capabilities would matter without the ability to deliver reliable product. Despite having to reinvent the wheel for every appliance or embedded system platform it manufactures, the company has developed a proven formula to handle high variability as well as high volume without sacrificing quality. For MBX, variety is the spice of business and the engine of company growth. A

ASSEMBLY ONLINE For more information on lean manufacturing and flexible assembly, visit www.assemblymag. com to read these articles: The Build-to-Order Challenge. Mass Customization Demands New Thinking. Time for a New Paradigm.


ASSEMBLY

Screwdriving

Automation for Small Screws Tiny fasteners present big problems for assemblers.

Tiny screws are used in a wide range of applications in the consumer electronics and medical device industries. Photo courtesy DEPRAG Inc.

For information on how to obtain reprints/e-prints of this article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516. By Austin Weber Senior Editor [email protected]

“I

t’s a Small World” is one of the most popular attractions at Disneyland and Disney World. The same phrase also applies to the manufacturing world

these days. With the proliferation of portable electronics, threaded fasteners are getting smaller and smaller. So, too, is the automated equipment to install them. Precision screwdrivers are now available to apply torque as low as 3 in-oz. As fasteners get tinier, they present big feeding and driving challenges to engineers. “Small” screws are typically defined as the diameter where the assembly time for a typical screw configuration starts to increase. “Generally, assembly times decrease with decreasing diameter,” says Dave Archer, president of Archetype Joint LLC. “I would estimate that this reversal starts at #4 (3 millimeter) fasteners on average. Whether manual or automated assembly, the greatest challenge is usually engaging the bit with the drive feature and maintaining that engagement while driving the screw.” “Small screws are defined by their size—typically 3 millimeter and smaller,” adds Mike Abbott, director of technical sales and licensing at Phillips Screw Co. “I further define ‘miniature screws’ to be in the 3 millimeter down to about 1.6 millimeter size range and ‘micro screws’ as 1.4 millimeter down to 0.6 millimeter or smaller.” “Another way to define or identify a small screw is the torque required to fasten it,” explains Boris Baeumler, applications engineer at DEPRAG Inc. “Screws with a 0.4 millimeter shaft may literally disappear underneath a


fingernail when trying to pick them out of a bin. When the screw is too small to be [manually handled], it is suited to equipment we specifically design for small screws. “We are seeing an increase in the demand for micro screw assembly solutions,” adds Baeumler. “Within the electronics and medical industries, there are countless new products that require small screws. As long as the screw has a shank diameter in a range that can be processed, then we can develop a solution.” Tiny screws are used in a wide variety of applications in the consumer electronics and medical device industries. For instance, they’re found in camera lenses, cell phones, e-readers, hard drives, hearing aids, laptop computers, microscopes, orthopedic implants, pacemakers and watches. Other applications include hand tools, sunglasses and toy trains. “The continued consumer-driven miniaturization of products is expanding the amount of micro manufacturing,” notes Jarrod Neff, marketing manager at Visumatic Industrial Products Inc. “Defense contractors [are also squeezing] greater functionality into compact tactical deployment envelopes.” “Weight reduction initiatives in the automotive industry [also] continue to drive demand for smaller, more complex components, and with it, the need for smaller screws and fasteners,” says Gene Simpson, vice president of quality and engineering at Semblex Corp. Compared to larger fasteners, miniature screws are difficult to handle, visually inspect and sort. Typical tolerances and feature sizes are also much smaller, requiring unique

This vibratory bowl automatically feeds small flat-head screws simultaneously to six screwdrivers. Photo courtesy Design Tool Inc.

measurement methods, tools and assembly processes. In addition, small screws tend to have short lengths. “A screw length that is less than 1.5 times the head diameter doesn’t orient itself well, which makes it difficult to feed, locate and pick up,” warns Abbott. “Handling small screws is not only visually difficult for operators, but physically difficult, too,” Abbott points out. “This work requires precision and lends itself best to operators with small hands, small tools and very good eyesight, including visual aids such as magnifying glasses and microscopes.” That’s why many manufacturers are forced to use automated assembly equipment. Feeding Challenges Orienting, presenting, picking and placing tiny screws often create unique challenges. For instance, blow feeding can create problems because the screws often want to tumble or bind in the feeder tube. “We have seen all types of feeding with small screws,” says Neil Maniccia, global product group manager for ASG Precision Fastening, a division of Jergens Inc. “We primarily have products which use vacuum pick up in conjunction with either a shaker box or screw presenter technology. Our technology is a variation of sword or drum technology.”

Automatic pistol screwfeeders are designed to access tight areas in assemblies. Photo courtesy Design Tool Inc.

Sometimes, engineers need to consider other feeding options, such as pick-and-place equipment or vibratory bowls. “We [typically specify] vibratory bowls, as we can fill and grind all gaps [without] giving the parts any place to hang up on or stick to,” notes Greg Pflum, president of Performance Feeders Inc. “Vibratory bowls also give us more options for tooling to correctly orient the parts. “The transfer point of the bowl to the gravity track or vibratory inline can be a problem area, due to the small screw size, including length and diameter,” explains Pflum. “Dirt holes also need to have attention paid to them to prevent good parts from getting stuck in them. “We typically look at using a scarfed or tongue in groove transfer point so that you do not have a straight gap between the two transfer points,” adds Pflum. “Another option is to have the bowl discharge higher than the track running surface and overlap them, so you drop the parts into the track, eliminating the gap problem. For dirt holes, we look at small slots or open areas where we hang the parts to [avoid] holes for the screws to get caught in.” One of the biggest challenges when feeding small screws is the overall length-to-head diameter ratio. “The closer that ratio is to 1-to-1, the more difficult it becomes to maintain the correct orientation of the screw in the feed

escapement mechanism,” claims Vic Glenn, president of Design Tool Inc. “With smaller screws, the tolerances of the feed components must be held more closely (tighter) to ensure that the mechanism will function correctly,” says Glenn. “Some small screws are difficult to orientate in the bowl before entering the feed mechanism because of the weight and size of the head. “[We are] addressing the challenge of feeding smaller screws with custom designs of our feed systems, including slide systems that control the screw until it is released into the feed tube,” Glenn points out. “Our patented feed systems are very adaptable for smaller screw applications.” Design Tool typically uses vibratory feeder bowl systems for small screws. However, the scale of the feed orientation and escapement components becomes smaller with small screws. “The primary challenges in driving small screws with an auto feed system are maintaining the correct screw orientation within the screwdriver components and clearance around the screw head for the driver components to access locations in the customer’s assembly parts. “Our driver components can be designed to fit into small areas and still allow the screw to exit the driver,” claims Glenn. “Also, we offer different types of drivers that enable us to successfully


Screwdriving

The scale of the feed orientation and escapement components becomes smaller with small screws. Photo courtesy Design Tool Inc.

drive most small screw applications.” Whether a screw is steel, brass or plastic, the same basic feeding techniques typically apply. If a screw can’t be blow-fed, vacuum is the preferred pick-up solution. However, the type of material a screw is made of can affect the type of automation that can be used. For example, nonferrous material will require vacuum solutions instead of pick-up tools that incorporate magnets. “As ferrous screws get smaller, the behavior of magnetic tooling is more inconsistent,” says Baeumler. “In most cases, vacuum tooling or mechanical gripping would be used to manipulate the smaller screws if blow feeding is not an option. But, even the slightest magnification amongst the screws can disrupt the screw sorting and movement. [That’s why] our smallest feeder uses a piezo driver rather than an electromagnet drive.” Driving Issues Small screws pose several driving challenges. For example, orienting a screw to the driver bit, holding it in place, and then driving the screw to its correct assembly torque can cause headaches for engineers. Screwdriver end-load, speed and shut-off are critical to driving and controlling assembly torque. “Stripping, cross threading and driver cam out are all challenges,” says Leon Attarian, director of global marketing at PennEngineering. Other

See us at ATX Texas, Booth 1513 42 ASSEMBLY / February 2012 www.assemblymag.com

issues that must be addressed include thread pitch, head diameter, head height, overall length, diameter of the screw and application access. “While we do offer small screws, we encourage our customers to reduce the amount of loose hardware, including screws, in their assemblies,” notes Attarian. “Our new self-clinching fastener will replace screws in many applications.” With small screws, the competence of the screw supplier is critical. Tight tolerances are essential. According to Visumatic’s Neff, platings and coatings, such as lubricants and organophosphate coatings, can limit automation options available to engineers. “There can also be quite a bit of frictional variation between contact surfaces during joining which often gets exaggerated by imperfections, especially in low-cost materials,” warns Neff. “Sometimes, just one extra thread can make all the difference in achieving repeatable screw drives.” “The screwdriver also has to offer the required torque range and high shut-off accuracy,” claims Baeumler. “A tiny screw will not allow for a big tolerance window in terms of torque, as the chances are high that the screw or the product may fail. “All in all, small screws demand a total view on the assembly task,” Baeumler points out. “The challenges must not be underestimated and can be extensive.

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This screwdriver is about the size of a ballpoint pen. Photo courtesy DEPRAG Inc.

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“Extra consideration has to be given to ensure that the end tooling and the drive bit are perfectly aligned for repeatable insertion and that the low torque values are accurately applied,” Baeumler points out. “The tolerances in the driveline of the standard industry screwdriver [are not conducive to] driving small screws and have to be compensated using ‘add on’ techniques in many cases.” For very small screws, Baeumler says the industry standard 0.25-inch hex drive may not be viable due to the tolerance implications toward the axial bit position and, more importantly, the torque accuracy required in such a low range. “The bit tip design and accuracy have to be suited for small screws and made extremely accurate,” he claims. DEPRAG has addressed those challenges by developing micro- and nano-sized screwdrivers that are the size of a ballpoint pen. The NANOMAT is a pneumatic screwdriver with mechanic shut-off clutch. The NANOMAT-EC is a current-controlled screwdriver that features torque and angle monitoring, and joint analysis functions. A www.assemblymag.com February 2012 / ASSE M B LY 43

ASSEMBLY

Welding

Adaptive Control of Resistance Welding A new technology could reduce, or even eliminate, the need for destructive and nondestructive testing of robotically welded joints.

The global automotive marketplace demands the highest quality performance and throughput from automated welding systems. Photo courtesy Bosch Rexroth Corp.

For information on how to obtain reprints/e-prints of this article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516. By Tom Taylor Branch Manager for Automotive Sales Bosch Rexroth Corp. Hoffman Estates, IL

I

ncreasingly, the global automotive market is placing a premium on the quality and durability of every car manufactured, not just those in the luxury segment. Models in every vehicle segment need to be produced with the highest levels of precision, fit and finish, and structural integrity to protect the vehicle’s value— and the competitive strength of the manufacturer’s brand across the globe. To achieve these goals, manufacturers are investing heavily in digitally controlled automated assembly systems. These systems offer two advantages: high-volume manufacturing of high-quality vehicles and detailed control of every key process. These systems capture and track a broad range of production data. High-speed, midfrequency, direct-current resistance welding is one such system. Robotic resistance welders can rapidly weld hundreds of parts per hour cost-effectively. However, to ensure the quality of each weld, engineers must periodically conduct destructive and ultrasonic testing of assemblies. Now, a new technology—adaptive control—has the potential to revolutionize the quality, flexibility and productivity of high-speed resistance welding, and it could obviate the need for follow-up testing of welded assemblies. Real-Time Control Adaptive control of resistance welding control uses unique hardware and software to precisely adjust welding


parameters, in real time, so every weld is performed within the tightest quality tolerances. Ultrasonic inspection of a welded joint is a manual process that involves taking a sample part from the assembly line and subjecting it to a standalone inspection. Based on the results of the test, engineers can then adjust current, time and other welding parameters. The problem is, ultrasonic inspection is time-consuming and not all that repeatable. The part only represents the quality of that particular welding process during a given production run. The sample doesn’t necessarily indicate what’s happening with every part. Moreover, the results can vary based on the tester’s opinion of what represents a good weld. By comparison, adaptive control integrates the inspection of each weld with the real-time control of how each weld is performed. This saves time, improves quality, and ensures that every weld is inspected and documented by the control system. Integration also maintains high levels of welding throughput. An adaptive control welding system, such as the PSQ 6000 made by Bosch Rexroth, monitors current, voltage and resistance parameters once per millisecond during automated welding. These parameters are constantly compared in real time against a previously established master resistance curve that controls the quality of the process. This master resistance curve is generated through a mathematical calculation of previously captured and stored current, voltage and resistance curves of known good welds. The PSQ 6000 automatically raises and lowers

welding current and weld time, in real time, to keep the actual parameter values as close as possible to those of the master curve—with the anticipated result that each weld will have equivalent quality. The adaptive control system measures the current and voltage at the electrode. Mathematical algorithms calculate resistance curves and energy balance. Data from the weld—such as the process stability factor, weld quality factor and explosion—are stored and made available for monitoring and trend analysis. The current is then adjusted to compensate for minute differences as welding proceeds. In special circumstances, sheet combinations with different thicknesses and coatings can be welded by a single program for special process applications, such as manual welding. This kind of control enhances welding flexibility, so manufacturers can be more responsive to fast-changing market needs. The automated platform can store and operate multiple welding schedules, and allows manufacturers to quickly change welding schedules for different components and body types. Welding Process Repeatability Manufacturers seek weld reliability, which helps them consistently meet their production and quality requirements. Unfortunately, every welding process is subject to variations. For resistance welding, these include part fit up and thickness, misaligned electrodes, coating material composition or thickness, sealers, weld force, shunting and machine tooling degradation. Welding gun tip wear is another factor that can affect weld reliability. Most manufacturers control tip wear through regular weld testing. Unfortunately, dozens or even hundreds of components might be welded before periodic testing uncovers a problem with worn electrode tips. In contrast, adaptive control of resistance welding automatically compensates for output changes as gun tips wear. Equally important, adaptive control provides an information

Real-time adaptive control of high-speed welding systems is crucial to maintaining the highest levels of product quality. Photo courtesy Bosch Rexroth Corp.

framework to assure manufacturers that weld reliability is actually being achieved. Because 100 percent of the welds are inspected in real time, the platform captures a record of each weld and any variations the controller made to ensure that the weld was within the established parameters. In terms of process control, this is a significant improvement over projecting weld quality from results obtained by manual product sampling. Improved Safety Many automated resistance welding operations have multiple robots performing hundreds of welds per minute. Without real-time control, the robots deliver a constant flow of power to the guns, which, in certain instances and with certain materials, is more than necessary to complete the weld. The excess sparks pose an increased risk of explosion and worker injury, which lead to lost worker productivity and increased healthcare costs. Operations without real-time control also require enclosures and other expensive protective devices and procedures. Adaptive control receives real-time

feedback of conditions on a component’s surface and adjusts the current flow to just the right level to complete the weld without generating explosion. Some studies have shown that adaptive control also reduces overall energy consumption by welding tools. Besides increasing worker safety and operational quality, adaptive control reduces the dirt and contamination associated with explosions in the welding workspace. A cleaner work environment lessens the need for maintenance and the likelihood of particulates interfering with sensitive electronic connections, sensors and other production line equipment. The true value of any automation technology is measured in how it helps a manufacturer generate savings through improved productivity and lower manufacturing costs. While there are costs associated with adding adaptive control to a resistance welding platform, adaptive control can lower the total cost of a welding system in several ways: Significant reduction of testing costs, including labor, time, documentation, expense per part tested, and scrapped and testing materials.


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Rexroth’s PSQ 6000 adaptive welding system enables high-performance, real-time control of automated resistance welding. Photo courtesy Bosch Rexroth Corp.

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rebates and legal liability due to increased weld reliability. Lower production cost per part due to increased throughput from 100 percent weld inspection. Reduction of explosion-related costs due to a safer and cleaner workspace with less contaminants and better quality welds. To better illustrate the cost-saving potential of adaptive control, consider the following example. A resistance welding line with 14 robots performs 150 spot-welds per part and generates about 800 parts per day in three shifts. Even after factoring in the cost of the control’s components and programming, an automotive manufacturer could expect to reduce the cost of testing and quality control for resistance welding by more than 30 percent over six years. Equally important, this amount does not include savings associated with improved parts quality. Plus, automotive manufacturers can efficiently integrate and retrofit adaptive control into their existing resistance welding platforms. A

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DTI Screw Dispenser from Design Tool Inc. The DTI Screw Dispenser from Design Tool is designed to load a pre-determined number of fasteners into a cup and drop them into your hand. This gives the operator the correct number of fasteners every time and provides accountability to an operator. The systems are designed for most screws, bolts, and nuts.

Design Tool Inc. 1607 Norfolk Place SW Conover, NC 28613 800-627-3674 [email protected] Designtoolinc.com

Incorporates a graphical user interface that simplifies and enhances operator and test application interfacing especially when performing such system functions as:

Multi-Testing Multi-Fixture Control Calibration/Verification Gage R&R SPC Data Gathering

[email protected] www.itc-leaktest.com 586-254-3165


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ADVERTISE IN ASSEMBLY’S PRODUCT REVIEWS Portable Inspection of Leading Edge Radius

Cordless Power & Mobility

The LaserGauge® HS733LE sensor is used to inspect the edge radius and thickness of blades during the manufacturing process. With a scanning accuracy of ±0.0005 inches, the sensor captures and displays a complete profile of the edge radius, and the profile can be compared to a template generated from engineering data.

Get mobile with DEPRAG Cordless EC Screwdrivers: Operator-Friendly, High ShutOff Accuracy, Flexible, EnergyEfficient, Powerful, Easy Data Processing. Process-reliable assembly in spacelimited areas with a torque range of 2 to 50 Nm. Includes Charger & 2 Batteries. Optional Base Station allows the connection of up to 4 Screwdrives.

Origin Technologies Corporation 256-461-1313 www.origintech.com

DEPRAG, INC. 640 Hembry Street Lewisville, Texas 75057-4726 972 221 8731 main 972 221 8163 fax 1 800 4 DEPRAG toll-free Catalog request: [email protected] General e-mail: [email protected]

Contact your sales representative for details. Barbara Grim 856-358-4800

Bill DeYoe 704-822-6434

Tina Vulgaris 847-405-4070

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Single-Source Part Feeding Manufacturer

Air Consumption Reduced by 90%

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here are times when the you need more than just a feed system. Performance Feeders has incorporated the Auto-Kinetics conveyor and extrusion frame line in our mix of products. This creates a single point of contact for you which saves time and potential mistakes. In this case our customer needed to convey the parts from their molding machine to an assembly machine. Using a cleated Z conveyor, we were able to move the parts up to a storage conveyor. From the storage conveyor the parts were fed into a vibratory feeder where the parts were split into two lines and oriented. From the vibratory feeder the parts were brought vertically down a gravity track where they were released one at a time into the customer’s receiver. Performance Feeders was able to handle the entire project giving the customer a single contact point for their part handling needs. Whether your feeding project consist of a single feeder or multiple feed and conveying systems, contact us to discuss your requirements. Performance Feeders is ready to help you succeed with your project. PERFORMANCE FEEDERS Performance “Built-In” By Professionals MANUFACTURER OF CUSTOM PARTS HANDLING SYSTEMS Phone: 813-855-2685 [email protected] www.performancefeeders.com

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ncreasing energy costs, legal requirements, and the demands of climate protection, make the efficient use of energy an important competitive factor today. Efficiency is much more than simple energy efficiency, especially when considering the time- and cost aspects. Enormous benefits are achieved with pneumatically actuated gripping systems with fully integrated micro valves from SCHUNK. They noticeably minimize airand energy consumption, while providing high cycle times. The smaller the actuator, the higher the efficiency, therefore micro valves which are used for small component handling and assembly can cut cycle times in half. Electrically driven pneumatic valves are now so small, that they can be directly located at the actuator and the consumption of expensive compressed air is massively reduced. Up to now, the compressed air of the air line supply is completely lost. If micro valves are used, just the piston area of the actuator has to be filled once with compressed air, and not the complete air supply line per cycle. In most cases, this reduces air consumption by up to 90%, and accelerates the response characteristics of the actuator.

211 Kitty Hawk Drive Morrisville, NC 27560 Phone: 919-572-2705 Toll Free: 800-772-4865 Fax: 919-572-2818 www.schunk.com [email protected] www.assemblymag.com February 2012 / ASSE M B LY 51

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Robotic Screw Fastening Work Cell

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ATI Provides Tool Changing Solution for Hollow-Wrist Robots

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tier one automotive supplier was challenged by their customer to automate the building of a special pump for a GM car. The final pump consisted of six subassemblies that required soldering of pins and wires, and screw fastening on four of the assemblies. Fancort delivered a solution for their lean manufacturing cell that consisted of two screw fastening robots for four different subassemblies and one soldering robot for use on two subassemblies. The requirements were high production and zero defects at each stage of the build cycle. The screw fastening robot, illustrated here, was a desktop robot with two feeders and a fixture that held three subassemblies. One feeder was for a torx screw and the other for a torx with captive washer. The driver was a servodriver with very tight torque tolerance of +/-3% and a series of QC controls that would prevent any part from being assembled incorrectly. The soldering robot was also a desktop from Japan UNIX that was fixture and programmed by Fancort to solder two wires to surface mount terminals on one subassembly, and solder pins to another PCB. The application was lead-free soldering so the robot included a nitrogen generator blowing hot nitrogen around the solder tip. The customer was so pleased with the results, they have order two more sets of three robots for two new cells. For information on Fancort robotic solutions for soldering, screw fastening or PCB routing, contact us at 1-888-fancort, or www.fancort.com FANCORT INDUSTRIES, INC. 31 Fairfield Pl. West Caldwell, NJ 07006 1-888-fancort Email: [email protected] Website: www.fancort.com


any of today’s standard industrial automation robots require large complex cable and hose bundles around the outside of the robot arm. Much consideration must be made to properly route the bundles around moving parts and robot axes and away from potential environmental threats, such as weld debris. Robot manufacturers are now offering hollow-wrist robots, where the dress package can be routed through the center of the wrist, keeping all cables and hoses internal, shielding the dress package from mechanical influences, and preventing undesirable whiplash motion. Gripper cables can be routed through the hollow wrist, resulting in better access into tight spaces and less problems with broken hoses and cables. Developed by ATI Industrial Automation, the QC-21HM Hollow-Wrist Tool Changer is being used on a bathroom accessories assembly operation with direct mounting to a FANUC M20ia robot. Brett Schmahl (Bemis Manufacturing) states, “There is a lot of highspeed motion and the robot internal wire way provides a great way of cleaning up the end-of-arm tooling wiring and hosing. With a standard Tool Changer, I wouldn’t have been able to utilize this space as easily. The HollowWrist Tool Changer is much cleaner and protects all the wires and cables”. ATI Industrial Automation celebrates their 20 year anniversary as the leading engineering-based developer of robotic accessories and robot arm tooling. ATI’s engineering department, the largest of its kind for a robotic tooling company, is focused on developing costeffective, state-of-the-art products and solutions. ATI Industrial Automation 1031 Goodworth Drive Apex, NC 27539 Phone: 919-772-0115 Fax: 919-772-8259 Email: [email protected] Web site: www.ati-ia.com

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Spec in Reliability – Spec in Loctite® Anaerobics

Foundry Cuts Energy Costs with Baldor Motors

Loctite® anaerobic adhesives include threadlockers, thread sealants, gasket/flange sealants and retaining compounds. These adhesives are comprised of unique resins that harden (or cure) to a durable solid when exposed to metal ions in the absence of air. The anaerobic cure mechanism allows adhesive to flow and evenly settle into a durable solid to lock, seal and prevent corrosion. Loctite® Threadlockers – in the red bottle – for threaded assemblies: Available in high-strength permanent (red), medium-strength removable (blue), low-strength and wicking grade. Liquid, stick and tape forms available. Loctite® Thread Sealants – for instantly sealing fittings & pipe threads: Thread sealants prevent leakage of gases and liquids from pipe joints subjected to vibration, changing pressures or changing temperatures. Unlike conventional pipe dopes and thread tapes, Loctite® solvent-free thread sealants also prevent corrosion and galling. Loctite® Gasket & Flange Sealants – superior to conventional methods: Loctite® gasket and flange sealants provide a low cost, high quality alternative to conventional hard gaskets. Allowing flexibility in design, Loctite® sealants include cured-in-place, elastomeric, silicone, light cure and RTV varieties. Loctite® Retaining Compounds – for shrink, press and slip fit assemblies: Retaining compounds fill the “inner space” between components and cure to form a strong, precision assembly. Available in general purpose and high temperature compounds for close and loose fitting parts. Loctite® retaining compounds prevent fretting corrosion from shock and vibration once the joint is sealed, and eliminate costly fatigue cracking and downtime. Henkel Corporation One Henkel Way Rocky Hill, CT 06067 1-800-LOCTITE (800-562-8483) www.henkelna.com/industrial

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or nearly 100 years, Benton Foundry has produced gray iron and ductile iron parts. Today the foundry serves more than 400 customers with 8,000 active part numbers. However, creating these products consumes a great deal of electricity, mainly through electric motors. In an effort to combat rising energy costs, foundry owners began a search for the most energy efficient motor they could find. After looking at a variety of motors from a number of manufacturers, owners chose to standardize on THE "ALDORs2ELIANCE® 3UPER %® MOTOR h4HIS MOTOR offers the highest efficiency ratings versus others in the marketplace,” states Jeff Hall, manufacturing vice president for Benton Foundry. “When you take a look at the cents per kilowatt and hours that these motors run, the improved efficiencies of the Baldor product mean the payback can be in as little as 18 months. When you consider how many years these motors will last, choosing THE"ALDORs2ELIANCE3UPER %MAKESTHEMOSTSENSEv Not only are these motors efficient, they run cooler and longer with greater reliability than any other industrial motor. That’s why today you’ll find more than 100 3UPER % MOTORS THROUGHOUT THE "ENTON &OUNDRY WITH plans to add others as older motors fail. With a wide selection of premium efficient motors available from stock, manufactured and sold by a company committed to building products for industries worldwide, ITSNOWONDERTHE"ALDORs2ELIANCEBRANDISRECOGNIZEDAS the leader in energy efficient industrial motors. Baldor Electric Company 5711 R.S. Boreham, Jr. St. Fort Smith, AR 72901 Phone: (479) 646-4711 www.baldor.com


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Robots Cut Flashlight Assembly Costs

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ureFire LLC, located in Fountain Valley, Calif., manufactures professional-grade, highintensity flashlights. As part of its continual streamlining process, SureFire began using robots to replace its hard-automation equipment and also to automate previously semiautomated lean cells. The robots have had several benefits, including reduced labor; higher output; more consistent quality, resulting in reduced scrap and rework; less use of factory floor space; and a faster ROI than hard-automation equipment. In one of its robot cells, a DENSO VS-Series six-axis articulated robot presents parts to a laser, which engraves product information on up to four sides. Previously, an operator had to load and unload parts onto an indexing table once for each side to be engraved. Now with the robot, the operator has to load and unload parts only once, and can run multiple cells. Cycle time has been cut in half, doubling output. In another cell, a DENSO six-axis articulated robot assembles flashlight tail caps. Here, a single robot performs multiple functions formerly requiring five different operators, each at a separate station, plus an additional operator to load and unload parts. The new cell occupies much less floor space, and requires only one operator, reducing labor costs. As with the first cell, cycle time has been cut in half, doubling output. Daniel Fischer, SureFire’s vice president of assembly operations, did all the integration in house, with parts fabricated in the company’s machine shop. “In-house integration isn’t for everyone, but for us it had a lot of advantages,” he said. “ROI is pretty fast this way. Running two shifts, it’s only a little over a year.”

DENSO Robotics 3900 Via Oro Avenue Long Beach, CA 90810 888-4-ROBOTX (888-476-2689) www.densorobotics.com 54 ASSEMBLY / February 2012 www.assemblymag.com

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Leak Test Eliminates Bottlenecks

Appliance Adhesive Dispensing Improves Quality Reduces Cost

The Challenge InterTech engineers another unique solution to in-line, high-speed production leak testing for a major manufacturer of diesel engines: eliminate the possibility of leak-associated defects getting through the system; provide accurate results in seconds; avoid wasting time and money on hot test repeats. The InterTech Solution Our patented technology dry air tests both water side and oil side at the same time, shortening test cycle time, virtually eliminating assembly line rejects, achieving significant time-cost savings. The water side includes engine block passages, water pump, heater housing, thermostat housing, associated hoses and the coolant half of the lube-oil cooler, creating a cavity of about 12 liters. The oil side includes engine block passages plus, front and rear gear flywall housings, crankshaft seals, oil pan, intake manifold and the oil half of the lube-oil cooler. This creates a cavity of up to 180 liters. Our system avoids problems of pressure fluctuation in the supply line by using isolated air reservoirs independent of plant air supply to provide a direct and stable leak measurement. Testing both cavities simultaneously at different pressures verifies the integrity of the critical oil/water seals. The independent circuits maintain pressure to enable rework and confirm that defects have been repaired. The Results InterTech M1075 delivered test results in 40 seconds, twice as fast as other available options. The customer reported our solution reduced hot test repeats by 50% and paid for itself in a few months. For worldwide solutions to your leak detection problems, call today.

InterTech Development Company 7401 N. Linder Avenue Skokie, IL 6077, USA 847.679.3377 Fax: 847.679.3391 email [email protected] www.intertechdevelopment.com

Situation: A major appliance manufacturer was using very high bond double-sided adhesive tape to bond glass to metal oven doors. To ensure correct placement, slotted templates was used for workers to locate up to 15 pieces of tape on the door. The workers wore protective gloves and arm socks and then manually cut tape. Issues included: tape sticks to the gloves, time to position tape, some tape in the wrong locations, quality control and inability to increase production rate. Study: After a performance study it was determined that a better process was needed to replace the tape and placement of adhesive to ensure product quality of the appliance and ability to meet production demands. The appliance engineers worked with adhesive and process equipment suppliers to determine the right adhesive and equipment to optimize cost and quality. Solution: Sealant Equipment worked closely with the engineers to develop a unique and low cost robot dispensing system that would apply a two-part high temperature silicone or acrylic adhesive to the metal door. A 2-station and 6-station robot dispensing system for manual load/unload and operated by one small 6-axis robot was manufactured and integrated by Sealant Equipment with their Servo-Flo 505 meter-mix dispense system. Production rates, cost and quality now meet customer requirements.

Sealant Equipment & Engineering, Inc. www.SealantEquipment.com/robot-dispensing.htm [email protected] www.assemblymag.com February 2012 / ASSE M B LY 55

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Workstations PUT Efficient Wire Harness Assembly Within Reach Of Jet Aircraft Manufacturer

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olerances have to be consistently tight when you’re assembling wire harnesses for a jet fighter – 1/8 of an inch over 32 feet to be exact. An assembly workstation that can’t accommodate such tolerances would be, well, intolerable. That’s one of the problems that a jet aircraft manufacturer faced when they determined that they needed to upgrade their facility. Another problem was the ergonomic failings of their old system. They were using pieces of plywood on A-frames for the assembly of extremely elaborate wire harnesses. This not only affected tolerance levels but also led to potential technician stress, strain and fatigue. Harnessing an ergonomically sound solution The jet fighter manufacturer found a company that could deliver exactly what they were looking for in Pro-Line of Haverhill, MA, a company recognized as a leader in modular ergonomic workstations. A company renowned not just for its rugged, technologically advanced workstations, but also for its ability to “think on the fly” and produce, application-specific solutions, Pro-Line delivered Electric Wire Harness Workstations, each retrofitted with a range of accessories. Pro-Line modified its existing technology with new technologies to produce a solution that was ergonomically sound, provided maximum functionality, and met all of the jet manufacturer’s specs. Thanks to the range of easy vertical movement provided by the Pro-Line system, along with the tilt, all sections of the wire harness are always within easy reach. Since this initial installation, this jet plane manufacturer has added new accessories to its workstation system, and is currently in the process of expanding its operation with additional Pro-Line workstations. Clearly they are more than satisfied that they have harnessed such precise, ergonomically sound and productivity-enhancing workstation solutions. Pro-Line 10 Avco Rd Haverhill, MA 01835 P: (978) 521-2600 * Toll Free: (800) 739-9067 www.1proline.com or www.industrialworkbenches.com


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Hand Crimping is Obsolete with the Perfect Pair

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panning across 22 countries with more than 59 facilities, Jabil Inc. has been serving industries ranging from consumer products to aerospace and defense. Founded in 1966, Jabil is an electronics solutions company providing comprehensive electronics for design, manufacturing and product management services. Jabil entered the automotive market working with wires and cables anywhere from 18 -10 AWG. Beginning with lower volume projects, they chose to hand crimp their wires using crimping pliers. This resulted in throughput issues and exposed potential quality issues they were not comfortable accepting. Jabil sought out Schleuniger, “Switching from hand operations to machinery made sense financially and from a quality risk avoidance standpoint; our operation becoming efficient and effective. We had witnessed how quickly Schleuniger got other companies up and running, some even in just 3 months. Schleuniger had a proven track record of being able to get even new and inexperienced customers up and running quickly,” Project Proposal Manager, Chris Hempsall stated. With the UniCrimp 200 and the UniStrip 2300, Jabil employees no longer have to measure, cut, and strip wires by hand; it is done automatically, programmed through the user-friendly display. Producing crimped wires 10 times faster than before Schleuniger arrived, Jabil no longer has concern for productivity and quality. “Schleuniger employees truly get the credit for our improved quality and efficiency,” Hempsall further stated. “The training they provided exceeded our expectations. We are beyond impressed. They quickly got us up and running and most importantly comfortable with technology we had little prior experience with.” Schleuniger, Inc. 87 Colin Drive Manchester, NH 03103 P (603) 668-8117 F (603) 668-8119 Toll Free Technical Support: (877) 902-1470 [email protected] www.schleuniger-na.com

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SINTECO Automated Assembly Line For Over 30 Components

Creform AGV Tuggers Automate ASSEMBLY Line For Mower Manufacturer

The Challenge: Design and development of an automated assembly line able to assemble, in-line test and package a German made product for a leading brand in the electro-mechanical sector and addressed to the international market. The Sinteco Solution: This one of-a-kind assembly line created by the Sinteco division of Bucci Industries features, in an area of approx. 2200 square feet, innovative concepts for planning and manufacturing, allowing the assembly of over 30 components in a cycle-time of 1 second. The assembly equipment extends along 3 synchronized mechanical linear transfers, patented by Sinteco, with 2 ending index tables: one for quality control and one for palletizing and packaging, on which 3 Scara robots are operating. The 3 transfer lines are mechanical cam driven, directly controlling a patented pick and place system with exceptionally high performances. Part feeding is performed by bowl feeders and by integrated vision systems to guarantee a fast set-up. The entire assembly line is unmanned. A unique feature of this equipment is its capability of combining high speed with the variation of the product. For this reason the line features a dedicated area for handling the common components and another one for the variable ones. Sinteco through expertise and intensive simultaneous engineering, has been able to develop the perfect customized, automated assembly solution, combining high productivity, good flexibility, conformity to the highest standards, process consistency and 100% traceability and reliability with its unique in-line quality check. Sinteco continues to invest and explore new technologies, new applications, new challenges motivated by the desire to innovate and to manufacture custommade automated assembly lines. SINTECO, Division of BUCCI INDUSTRIES 9332 Forsyth Park Drive Charlotte, NC 28273 Phone: 704-583-8341, Fax: 704-583-8486 www.bucci-industries.us, www.sintecorobotics.com

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manufacturer of commercial lawn mowers looked to Creform to improve production efficiencies in its assembly line. The company was using an ineffective automation system and was not meeting production objectives. Creform engineers designed and implemented a system utilizing Creform BST style AGV tuggers and delivery carts that has kept the assembly stations producing optimally. The new system consists of 18 Creform BST AGV tuggers, each pulling two carts to 18 stop stations on an approximate half-mile course. Each AGV picks up a mower frame at the paint line on its first cart. The next stop is parts kitting where the second cart is loaded with sequenced kitted parts. Proceeding through the assembly area it reaches the end dropping off a finished mower then returns to the paint line starting point. A traffic controller wirelessly communicates with each stop station verifying each AGV’s position and optically connects to AGVs while at each stop station. Stop stations feature wirelessly connected “operationcomplete” pushbuttons that when activated signal the traffic controller that work is completed. After receiving all 18 operation-complete signals it simultaneously releases the AGVs keeping vehicles properly spread throughout the system, avoiding congestion and maintaining order on the assembly line. Battery chargers with retractable cords are located at each stop station. At the end of a shift, operators need only turn off the AGV and plug in the battery charger. When work resumes the AGVs are fully charged and ready to function. The new Creform system is operating efficiently and reliably while meeting production objectives. Creform Corporation 800.839.8823 [email protected] www.creform.com www.assemblymag.com February 2012 / ASSE M B LY 57

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ATC Automation Controls the Solution

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TC Automation was recently approached to provide a large, automated assembly and test solution with some unique challenges. The customer required an extensive data collection and traceability system that was free of human interaction and that maximized through put. A palletized conveyor system was designed that transported the product from station to station. ATC’s control engineers developed a system that alleviated any “bottle necks” by staging pallets at station pre-stops. This insured the system never “starved” for product or had any operator interaction. The pallets were designed “two-up” and accommodated different sizes and SKU’s. As a result of planning and engineering, ATC was able to reduced expensive pallets while maximizing flexibility. Meeting the required through put during the laser welding processes also posed a challenge. Laser welding was required at several stages of the assembly process. For accuracy, the parts were automatically removed from the pallet and located in separate tooling to provide a highly precision weld. By balancing the stations and utilizing a unique “time share” process, multiple lasers were able to deliver the precise laser power needed for the weld. A RFID system was developed to automatically identify and track each part of the product’s assembly processes. Once identified with the RFID system, a data collection system was designed that recorded the processes ensuring the customer had ready access to the variable data. Innovation and experience with pallets, tooling, laser welding, and controls enabled ATC to build this system. The desired cycle time was met and all the necessary data was identified and recorded for traceability. ATC Automation 101 Mill Drive Cookeville, TN 38501 Phone: (931) 528-5417 Fax: (931) 526-3901 www.automationtool.com


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Machine Builder, Ingersoll Saves 60% with Balluff’s IO-Link

A traditional I/O system consumes more cabinet space and requires longer I/O cable runs (top). The new Balluff IO-Link System allows for more decentralization of I/O and reduced cabinet area (bottom).

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hen Ingersoll CM Systems decided to build their next generation deep fillet rolling machine, they were looking to create a more modular and expandable machine that would allow their customers to easily keep pace with evolving crankshaft sizes. After testing several I/O networking options in the market, Ingersoll determined that Balluff’s IO-Link solution would be the best option to decrease cost and the number of components per machine. Gary Munger, Controls Engineering Manager for Ingersoll, said “The IO-Link solution resulted in a 60% cost savings over our previous I/O modules. The savings came from reducing the number of components used in the machine and using the more economical IO-Link hubs.” Gary added, “Reducing the number and complexity of the components also reduces the possibility of failures for our customers.” IO-Link is an open, economical technology that allows for the expansion of networked I/O devices. By using low cost, standard M12 cables, the point-to-point wiring is the most cost-effective available. Balluff’s IO-Link hubs contain only the I/O circuits without the cost of the full network protocol. By building this new generation of deep fillet machines integrated with Balluff IO-Link technology, Ingersoll can pass on significant time and cost savings to their customers. Balluff, Inc. 8125 Holton Drive Florence, KY 41042 Phone: 1-800-543-8390 Web: mailto:[email protected] [email protected]

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Compact Grippers Stack for Increased Productivity

25 years of performance, right out of the box.

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m a n u fa c t u r e r o f packaging and filling machinery had an application that involved an “X-Y” motion device with eight grippers attached to the tooling plate. The grippers loaded eight small parts simultaneously into multiple containers. Even though it is not a wash down application, the grippers needed to have stainless steel tips for contact with the part in this food packaging process. The customer’s application required a gripper that was small and very precise. The PHD Series GRA Gripper was an ideal fit for the customer’s requirements. The GRA Grippers feature a compact flexible design providing large moment capacities and long tooling length. They utilize an ultra precision jaw guidance system minimizing free-play and reducing deflection for exceptional performance. The robust construction ensures long operating life while providing a high level of performance for a wide range of small part handling requirements. They are available in four sizes for increased application requirements. Optional manifold ports are available so that the grippers can be mounted together for increased compactness. Additionally, PHD’s Unique Solutions Group worked directly with the customer to provide the design of the stainless steel jaws for the application. The jaws were designed to match the customer’s specifications eliminating the need for separate jaw tooling. A change to food-grade lube was made and incorporated into the GRA Gripper specifications. Once the specification was done and the customer approved the design, the unit was tested. The PHD GRA Gripper worked better then they anticipated. The test validated the grippers, finger design and materials used. This solution has been utilized many times since that initial design resulting in superior performance. PHD, Inc. 9009 Clubridge Drive Fort Wayne, IN 46809 Tel: 260-747-6151 www.phdinc.com [email protected]

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EPRAG is proud to introduce the new modular DCAM, offering a reliable, compact, standardized assembly platform with a high level of functional safety…right out of the box. The modular DCAM is now more cost effective with shorter delivery times. The DCAM was developed when mobile phone assembly was still in its infancy. Mobile phones used to be assembled by hand - an expensive and time-consuming process. A Swedish mobile phone manufacturer sought help from DEPRAG to produce mobile phones faster and more cost effectively. Many work sessions later, the DCAM assembly platform, now valued throughout the world, was born. Dubbed the Weasel, the DCAM began its work. And with weasel-like speed it won over the Swedish mobile phone manufacturer, who immediately ordered the first hundred of these innovative assembly stations. The flexible DCAM is ideal for screwdriving assemblies as well as labeling, monitoring components, dispensing, joining and marking tasks. Now 25 years later the DCAM is better than ever. Lori Logan Marketing Mgr. DEPRAG, Inc. 640 Hembry Street Lewisville, TX 75057 (800) 4 DEPRAG (972) 221-8731 Ext. 3806 (972) 221-8163 Fax [email protected] www.depragusa.com www.assemblymag.com February 2012 / ASSE M B LY 59

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Clean, efficient Supertrak™ conveyor keeps pace with market demand

IAC Solves Nokia’s Deployment Needs

The Challenge Faced with increasing production demands, a customer in the life sciences industry turned to ATS Automation to replace their highly manual assembly system with one that would expand to support their growth. The Solution The ATS Pre Automation Solutions experts laid a foundation for success by meticulously mapping out automation configurations that could be implemented with minimal interruption to existing business processes. From there, a multidisciplinary ATS team fluidly moved in to implement an expandable, modular assembly system that only occupied a fraction of the space of conventional conveyor-based systems. The solution centered around ATS’ Supertrak™ conveyor – a breakthrough in highspeed pallet-based conveyance. The Supertrak conveyor’s clean, non-contact design is critical to keeping dust and dirt out of the customer’s clean room medical manufacturing environment. Being fully programmable, Supertrak conveyor gives the customer flexibility to set new positions and adjust processes without the need to add expensive components or wiring. With minimal training, the operations and maintenance staff were prepared to self-sufficiently run the system, with the knowledge that ATS was available if they needed support. The Result In the end, the customer was so pleased with the performance of Supertrak that they engaged ATS to repeat the success in a second facility. “The customer was looking for an expandable, modular type of assembly system to which they could easily add additional stations or tooling to keep pace with market demand,” explains Kris Drummond Project Manager with ATS Automation Life Sciences division. “Supertrak enabled us to easily meet those objectives, exceeding expectations along the way.” For more information contact: ATS Automation Alberto Quiroz Sales Manager - Products Tel: 1 866 546 8515 ext. 85324 [email protected] www.atsautomation.com 60 ASSEMBLY / February 2012 www.assemblymag.com

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n setting up their Ft. Worth manufacturing facility, cell phone manufacturer, Nokia Mobile was having difficulties ordering upgrades and getting the right parts for their assembly workstations. They were also dismayed that their current bench dealers shipped parts without providing any installation support. Nokia was looking for a product line that offered fast turn-around time on product orders and greater flexibility for upgrades. In reviewing alternatives, Nokia engineers became very interested in the Dimension 4 workstations from IAC industries built-to-order product lines, but the schedule would not allow for normal lead times. They were introduced to the IAC Quick Ship product line. The Dimension 4 Series featured in IAC’s Quick Ship product line offered enough variety, options and accessories to build workstations to Nokia’s desired functionality. By utilizing IAC’s Quick Ship program, Nokia was able to see their workstations shipped to Ft. Worth within 5 days instead of 4-6 weeks. The success of the initial Dimension 4 workstations won the confidence of Nokia engineers and ultimately resulted in the deployment of more that 300 workstations and workbenches. Nokia’s Factory Automation Specialist stated, “We had worked with two other bench companies in the past, sometimes with mixed results. IAC was able to provide everything we needed... excellent service, a flexible workstation, and delivery that suited our fast installation schedules.”

IAC Industries www.IACindustries.com 0( sBENCHSALES

IACINDUSTRIES

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Lightning-Quick Thred Taper™ Machine Plays Pivotal Role in Gulf Cleanup

Major Auto manufacture achieves fast and accurate production rebalancing using Elite Engineering’s eFlex assembly task configuration tool

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hen Arthur FST’s Rob Kernan was faced with an immediate deadline to wrap 1,300 parts needed for the Gulf oil cleanup, he knew the Thred Taper™ machine could help him get the job done. “We wrapped 1,300 parts in four hours, a feat that couldn’t have been accomplished without the Thred Taper machine,” said Kernan, the company’s operations manager. The Thred Taper machine is the world’s only automatic PTFE tape wrapping solution that speeds production, cuts costs and eliminates product failure due to inconsistent hand wrapping. Applying PTFE tape to most fittings in seconds, the machine helps increase productivity and component reliability while saving as much as 500 percent on tape consumption. Components wrapped by the Thred Taper machine provide a consistent seal that can be immediately pressuretested. Using a thicker PTFE tape, the machine requires far less material than standard tape-wrapping processes. It also provides deeper application of tape into the thread roots, resulting in a higher-quality seal. The machine uses a carefully calibrated PTFE tape dispenser that reduces material usage and waste by precisely controlling the number of wraps per fitting. The dispenser applies various widths of PTFE Tape to American Tapered, British Straight and Metric threads ranging from 1/8-in. to 2-in. NPT. The Thred Taper machine quickly applies a leak-proof seal to virtually any fitting. Just ask Kernan, who was able to meet his deadline thanks only to Thred Taper. Thred Taper™ Automatic Taping Machine Federal Process Corp. 4520 Richmond Rd. Cleveland, OH 44128 1-800-846-SEAL www.thredtaper.com

he new granularity is in hours and days not weeks and months! When there is a move in the market place and a change in demand, one plant manager reacted in weeks and months and the other reacted in hours and days. Which plant manager would you rather to be? An engine assembly line was ready to be launched producing a new engine. Market demand leading up to the launch supported production of 600 engines per day. Rapid changes in demand dictated a lower production rate of 400 engines per day. The PROBLEM is that the engine assembly line needed to be re-balanced and fast. Fortunately, this assembly line used eFlex Assembly, an easy-to-use assembly task configuration tool that lowers operations costs and model changeover times by executing fast, accurate and repeatable rebalancing of assembly tasks. The eFlex Assembly Framework allowed 1 Industrial Engineer to re-configure all 75 engine assembly workstations in approximately four hours. The re-balance involved over 400 process tasks, and 8 model variants. It was completed with zero errors due to the error proofing capability of the eFlex Framework. A similar engine assembly line currently in production that does NOT use eFlex, but instead uses a traditional PLC architecture and substantial programming was required to complete an equivalent rebalance. For this assembly line, re-balancing is a time-consuming activity necessitating extensive manual re-coding of the workstation PLC’s requiring 3 Controls Engineers approximately 2 months to re-program the 75 engine assembly workstations. Elite Engineering, Inc 6841 N. Rochester rd. 250C Rochester Hills, MI 48306 248-651-5979 www.eFlexAssembly.com


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Steering Housing Assembly with a Promess EMAP

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Clearing Bottlenecks in the Mountains: A Stäubli Robotics / Morrill Motors Case Study

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APPLICATION SUMMARY Using a hydraulic press to press a tube into the steering gear housing, our customer could not hold a constant distance on their part due to the inaccuracy of the press and the elasticity in the part. After pressing the part to a known distance the elasticity in the part would cause the part to spring back, making it very hard to keep tolerances. The greater the amount of force it takes to press the part in, the greater the elasticity. The customer has a tolerance of ± 0.200mm and with the hydraulic presses that they were using; they would go outside these tolerances quite often measuring parts between ± 0.350mm APPLICATION DETAILS Using the Promess 150kN press, along with an integrated software compensation factor, the customer was able to press their part to a critical dimension without overshooting the tolerance for the given part. The compensation factor is a linear distance based off of the rated load of the press. The forces from part to part were constantly changing, ranging from 60kN up to 135kN. Because of the elasticity in the parts, some parts needed to be pressed in farther so that when they would spring back, the final location would fall within the tolerance. A master part and an external position transducer were used to teach in the final location that every other part was to be pressed to. When running new parts the press would move down onto the part until it reached the master depth the press force was read, and depending on how much force the part was taking to be pressed together, the press would move a set distance father than the final location in order to compensate for the elasticity in the part. Promess Inc 11429 Grand River Road Brighton, MI 48116 810-229-9334 www.promessinc.com [email protected]


ver more than 60 years in business, Morrill Motors is a leading manufacturer of long life, 1- to 25-watt unit-bearing motors used in a wide variety of industrial, commercial and residential product applications. They can be found in everything from supermarket display cases and beer coolers to commercial ice machines and beverage dispensers. But for all its expertise in product performance, Morrill Motor’s Erwin plant was encountering problems in keeping its production line performing at peak. A human operator would first load a motor housing onto the mandrel on an Acme multi-spindle machine, then remove the part after the front side was machined. Another operator would load it on a Borematic single-spindle machine to finish the back side. This created productivity challenges that were tailor-made for a robotics solution. Vaughn, Process Engineer Kevin Penland, and other company decision-makers knew they needed a productivity-enhancing solution to these challenges. A Stäubli Model RX130 robot proved to have the ideal combination of speed, precision and reliability, creating true single piece flow. “Thanks to Stäubli Robotics” Vaughn says, “our throughput jumped 25 percent, raising part production from a low of 2,500 to a steady 3,700 parts a day. Instead of 4,000 parts in the line, there are typically just ten.” Stäubli Robotics has helped the company make cost reductions in a host of areas, and greatly improved its safety record, with zero injuries since the line was automated over a year ago. Parts loaders who wanted to stay on with the company moved into more satisfying jobs. Stäubli Corporation 201 Parkway west PO Box 189 Duncan, SC 29334 800-845-9193 www.staubli.com

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The Next Generation Screwdriver for Demanding Industrial Assembly

JP 4 Series ElectroPress Stabilizes Product Quality

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he modern industrial assembly lines of today require high torque accuracy, robust tools and consistent performance in order to meet productivity and quality requirements. The Desoutter SC2 pneumatic screwdriver range has been designed for heavy duty tasks that demand maximum torque accuracy, including self-tapping screws in plastics. Reliability and durability are the key features of the SC2 pneumatic screwdriver. When compared to standard screwdrivers, Desoutter’s SC2 solution brings quick return on investment based on savings from maintenance cost reductions, productivity and quality improvements. The wide torque range, from 4.4 to 57.2 in.lb (0.5 to 6.5 Nm) allows the same model of screwdriver to be used for a variety of tasks which simplifies maintenance and parts management. The Desoutter SC2 screwdriver’s straight body design has been engineered to provide maximum ergonomic comfort. The SC2 soft touch rubber and tapered shape ensures a steady grip without having to squeeze excessively. The new clamping area for fixturing enables the SC2 to be perfectly positioned for any application. In addition, it is Electrostatic Discharge (ESD) safe, making it suitable for assembly operations that handle microelectronic applications. The Desoutter SC2 comes standard with a built-in feedback unit for use with air tool qualifier systems. There are two pneumatic signals available for e.g. tool in cycle status or torque achieved status. This brings a high level of error proofing possibilities for a pneumatic screwdriver. All benefits mentioned lead to significantly lower cost of ownership compared to conventional screwdrivers. Desoutter Industrial Tools 1800 Overview Dr. Rock Hill, SC 29730 [email protected] Phone: (888) 298-2905

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leading manufacturer of motorsports products was challenged by their assembly process. The sum of tolerances regarding their dampers yielded final production components with large variations. Once the dampers were located in inventory it was almost impossible to pick a matched pair. This issue could cause the overall capability of the vehicle to be reduced. Creating a highly capable vehicle was the legacy of this motorsports mogul. Janome shares a similar history. The goal was to closely match the inventoried suspension parts for improved stability and overall quality of each vehicle. Parts that were not within tolerance needed to be rerouted for review and rework or scrap. Janome’s JP 4 series servo press was the solution selected for the task. A pressing program was called via bar code scan, configured to oscillate each part through it entire working range. Next, the press measured the real-time load according to the force profile sensors and would determine pass/fail of the part. Upon successfully meeting the sensor requirements, the press triggered a laser marking system responsible for etching an associated value on the damper body. That value would be use as a reference during final parts selection. The dampers could now be picked according to the reference number allowing for a more balanced vehicle characteristics and improved performance. The results were a fully automation quality control cell that identified 100% of parts that were out-ofspecification while providing 100% traceability. In addition, Janome’s JP 4 series press increased the quality and capability of the final assembly. Janome Industrial Equipment USA, Inc 892 Cambridge Dr. Elk Grove Village, IL. 60517 847-357-8870 www.janome-ie.com [email protected]


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AIMCO – Achieving Assembly Excellence

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IMCO, a leading marketer of industrial power tools used for assembly operations, was approached by an automotive company requesting them to analyze a particular application being utilized during their assembly process.The application involved using a controlled pulse tool; however, alarms were still being delivered due to the high torque. Once this occurs, the item must be inspected for tightening specifications; should the item be found with a torque that is too high, the item is considered “scrap” and must be dismantled and completely rebuilt with a new housing. AIMCO’s field expert identified that the system currently being utilized was too powerful for this specific application. The controller was outdated which limited some controlling features; the extension used allowed the operator to unknowingly influence the final torque. As the line speed is very quick, and the torque high, the preferred solution was to replace the old system with a new controller and transducerized pulse tool. AIMCO supplied the new controller and tool system along with an improved extension. AIMCO’S field expert worked closely with the maintenance team to install the trial system into their existing controls. After the new system was installed the company’s Quality Assurance team became involved in the project to verify the final torque was within specification. The system was allowed to run for approximately a week without any faults. In fact, prior to the system being installed, approximately 80 repairs took place. Currently, with the new system in place, they are averaging 3 to 5 repairs per week. Engineering easily justified the cost of a new system based on the substantial fault decrease as well as, increased productivity. Contact: Bobbi McConnell [email protected] (503) 254-6600 10000 SE Pine Street Portland, Oregon 97216


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age Bilt Inc, a Detroit Michigan based manufacturer of blind rivet and lock bolt tools since 1956, has been filling a niche market need for special riveting tools to meet unique customer requirements. In one such application an auto tier supplier of convertible roofs was looking for two tools with 26 foot hoses, remote hydraulic power units and mandrel vacuum capabilities. One tool was needed to install a 1/8” diameter blind rivet and the other was required to install a 3/16” diameter blind rivet. The 26 foot hose was needed so the operator could walk around the convertible roof frame and install the rivets. The Gage Bilt solution was to design of single tool with a special jaw system that could install both rivets. The addition of a mandrel collector bottle to the lightweight hand held tool eliminated the problems associated with vacuuming spent rivet mandrels over long distances of 26 feet. The collector bottle had adequate space to hold a full riveting cycle of both the 1/8 and 3/16 rivets. The operator would empty the bottle after one riveting cycle. The compact GB801 high output hydraulic power unit features a large glass reservoir with a hydraulic fluid level indicator line. This system assures hundreds of thousands riveting cycles without the need for priming as with conventional riveting tools. Gage Bilt Inc. 44766 Centre Court Clinton Township, MI 48038 PH. 586-226-1500 FAX. 586-226-1505 www.gagebilt.com [email protected]

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Combination Drilling/ Pinning Machine Saves Time & Money

New Ametek Lloyd Instruments Single Column Materials Testing Machine

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hydraulic pump manufacturer required a method to permanently affix various sized gears to shafts. After press fitting the gears into position, they would drill a hole partially through the assembly, install a heavy duty Coiled Spring Pin, and stake the entrance point for maximum security. This process was done manually using three different stations. SPIROL offered to consolidate all operations into one complete installation machine. The machine needed to be versatile enough to accommodate eleven existing gear/ shaft assembly sizes, as well as be able to handle new variations as designed. Tooling changeover had to be quick and simple, with little to no machine adjustment. The SPIROL Model DP machine consists of a standard Model CR Pin Insertion machine, an automatic, production quality, high-precision drilling unit, and a precision air-powered linear slide unit to move the assemblies between the drill unit and installation/staking station. Machine features include: Recirculating flood coolant in the drilling operation for temperature control and chip removal Automatic clamping/part holding fixture unit Easily interchangeable tooling to accommodate eleven different assemblies Common drilling and pin insertion elevation between all assemblies Pin presence sensing to verify a pin was installed in the assembly Allen Bradley Panel View™ Human Machine Interface for programming and control of all machine functions SPIROL’s solution provides a machine cycle time of 45 seconds and tooling change-over takes less than 15 minutes between assemblies. This machine doubled the previous production output, and provided a payback of less than 12 months.

SPIROL International Corporation http://www.spirol.com/s/automation_am/ [email protected]

new single-column materials testing machine from Lloyd Instruments provides enhanced speed, accuracy and flexibility for all materials testing applications under 1kN force. High-precision displacement measurement is assured by the Model LS1 instrument’s linear guide technology, pre-loaded ball screws and advanced software compensation systems. Industry applications include plastics, packaging, medical devices, automotive, electronics, textiles, rubber and pharmaceuticals. It can be used for tensile and compression testing, friction, tearing, peeling, insertion/extraction, creep/relaxation and many other measurements in manufacturing, product development and research. Available in standard (500mm) and extended (800mm) travel versions, the LS1 universal testing machine has an extended crosshead speed range from 0.01 – 2032 mm/ min. Load accuracy of +/- 0.5 down to 1% of load cell value provides high dynamic range, reducing the number of load cells required to cover the force range. The wide throat depth (180 mm) provides a large working area for sample placement. A more compact physical orientation takes up less side-to-side bench space than previous models. A new version of Lloyd Instruments’ NEXYGENPlus materials testing software allows flexible, intuitive setup and control by standard PC or laptop with USB interface. Handheld controllers and integrated control consoles also are available. Trend reports can be created for statistical quality control. AMETEK LLOYD has a posted specification sheet for the machine on www.lloyd-instruments.co.uk. We would welcome the opportunity to assist customers with material testing and force measurement applications.

AMETEK Test & Calibration Instruments Largo, FL 800-527-9999 727-538-6000 [email protected] www.assemblymag.com February 2012 / ASSE M B LY 65

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Servo Indexing For Eddy Current Testing

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oerster Systems Located in Salem, Ohio specializes in complete turnkey inspection solutions utilizing eddy current nondestructive testing methods for finished and semifinished metal products and components. One of Foerster’s recent challenges was to build an automated inspection system capable of testing seventeen sizes of forged steel components. Requirements included eddy current testing of material hardness and the gauging of numerous physical attributes including cross holes and hexes. The machine was centered about a rotary indexer capable of transporting components 45 degrees in ½ second, and positioning within +/- 30 arc seconds. Mechanical designer Jim Galich was looking for flexibility, performance, and ease of use. “We have used mechanical indexers in the past but Centricity’s servo indexer was a great solution for this application. We were able to integrate the indexer seamlessly, and the spreadsheet based software was simple to use. The compact design of Centricity’s EZ Indexer allowed us to position our tooling under the dial plate and significantly reduced the machine footprint.” Centricity supplied an EZ Indexer which includes the servomotor with digital AC controller, position feedback, cables, and simple-to-use spreadsheet based software. According to Galich, “The fact that Centricity’s servo indexers are competitively priced with the mechanical indexers we have used and are available from stock made selecting them an easy decision. Their knowledgeable staff ensured that the model and size selected exceeded the performance we demanded.” Centricity manufactures servo indexers, custom rotary tables, ID parts feeding systems, and powered and nonpowered rotary carousels.

www.centricity.net [email protected] TEL: 330-545-5624 Girard, OH 44420 66 ASSEMBLY / February 2012 www.assemblymag.com

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Multiple process monitoring for automotive application, no problem!

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he various steps in an automotive components assembly, may require various processes and quality monitoring techniques. Often an incorrectly assembled part won’t be detected until installed in a vehicle resulting in costly corrections. Burster’s 9307Digiforce is a monitoring platform, capable of accurately monitoring a variety of processes from Press Monitoring to Functional Testing. In one example, an automotive component manufacturer commissioned an assembly line that posed a number of monitoring challenges. The initial processes required the insertion of two pins into a cast housing. The insertion of the two pins occurred simultaneously with a common servo press. The Digiforce’s dual monitoring channels allowed the individual monitoring of both press fits with one 9307. The 9307 utilised the servo’s encoder for displacement tracking . Another station utilized a 9307Digiforce unit to monitor a spring insertion. A laser displacement sensor monitored the insertion and the 9307Digiforce was able to adjust the displacement parameters relation to a specific load . An end of line functional test was needed to ensure that the correct spring was inserted and inserted correctly. A functional test involved compressing the spring and monitoring the correct final compression displacement and the spring rate, as calculated within the 9307Digiforce. The optional Profibus provided communication with the PLC and graphical displays of the signature curves were displayed for each part. The acceptance/rejection criteria of the operation is available for serialized data storage. The Burster 9307Digiforce can monitor these processes with one flexible platform, as well as Torque, Resistance, Pressure, Gauging, etc. Physicom Corp. Physical Measurement and Data Communication Tel: 416 754 3168, Fax: 416 754 2351 [email protected] www.physicomcorp.com

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VarioFlow: Flexibility in Contract Packaging

Dispense Valves Help Company Save $70K a Year

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hen food product consumers’ tastes change, food product manufacturers’ processes need to change with them. Oak State Products (www. oakstate.com ), a contract packager and manufacturer of baked goods, was challenged to stay ahead of food product marketers’ demand for changes and adjustments to packaging styles in response to shifting consumer demands. When Oak State’s customers switched — i.e. from 2- or 3-pack cartons to open-pack trays — It was difficult to add or convert production lines because the space for product conveying was quite limited. Production line changeovers were also challenging because of space limitations. Working with experienced Rexroth integrator NCC Automated Systems (www.nccas.com), Oak State selected Rexroth VarioFlow single-strand flexible chain conveyors to help solve these challenges. Oak State had previously installed VarioFlow conveyors at its facility devoted to cartoning and packing, and was pleased with the results. VarioFlow modular conveyors are engineered for rapid system design, quick installation, and quick startup. VarioFlow blends a modular design with numerous product options to create a reliable, reconfigurable system. With high chain tensile strength (up to 1250 N) and low chain friction, VarioFlow promised reduced energy use, lower maintenance and longer service life. NCC integrators blended modular VarioFlow 90 and S 160 conveyors to enable efficient transport of products in wrapped sleeves, plastic trays and cartons – all within existing space limits. To ensure a well-coordinated system, designers included both inclining and declining conveyors, alpine conveyors and overhead transport, so packing and other machines worked efficiently alongside or underneath the conveyors. For more information go to www.boschrexroth-us. com/varioflow

Bosch Rexroth Corporation 14001 South Lakes Drive Charlotte, North Carolina 28273 800-REXROTH (739-7684) [email protected] www.boschrexroth-us.com

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manufacturer of furnace safety switches needed to calibrate their many product configurations to match each furnace company’s specifications. After the calibration screws are adjusted, the wells in which they sit are filled with adhesive to hold the screws in place. Workers used squeeze bottles to fill the wells with a water-based adhesive that was taking too long to cure before the switches could be packaged. The engineer tasked with improving the process decided to change to a fast-curing UV adhesive. Although the new adhesive cost 10 times more than the water-based one, analysis showed the extra cost would be offset by higher productivity. Four new dispensing/curing lines were designed. To dispense adhesive into the wells, the company purchased four Nordson EFD valve/controller systems. The compact valves combined fast, accurate dispensing with a clean, drip-free cutoff, while the microprocessorbased controllers made it easy to quickly adjust shot size for each switch configuration—without stopping the production line. Their investment in a new adhesive and better dispensing technology enabled the company to achieve impressive results: Between labor savings, higher output and less work-in-process, they will save $70,000 a year. Approximately 30% more parts are produced in the same amount of time. It took five minutes or more for the water-based adhesive to skin over enough for the switches to be packed. On the new lines, the new adhesive is applied and cured in just five seconds. Bottlenecks due to excessive work-in-process have been eliminated. Nordson EFD 40 Catamore Boulevard East Providence, RI 02914 Phone: 800-556-3484, 401-431-7000 FAX: 401-431-7079 Email: [email protected] Website: www.nordsonefd.com


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Micro Pin Insertion

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. Galow Co., Inc. needed a solution to automate the insertion of extremely small and hard to handle stainless steel pins into a long cylindrical rod for a medical application. The dimensions of the precision pins were 0.7mm in diameter by 2.2mm Overall length. Micro fasteners and other small parts are often extremely hard to feed in conventional sized vibratory bowl feeding equipment because of the size, tight tolerances, excessive vibration, and the high degree of accuracy /adjustability required to guarantee 100% feed out of the fasteners from the equipment. With tight tolerance parts, the danger of damaging or marking these expensive parts using normal feeding techniques is quite high. This application also called for accurate presentation of the pins into an escapement. Seeing a need for micro feeding solutions, Weber Screwdriving Systems Inc. developed a feeding solution for small fasteners by utilizing piezoelectric technology. The science behind piezo technology incorporates piezoelectric crystals that vibrate at different frequencies depending on the electronic voltage & current being passed through them. Weber USA undertook the development of a new version of the piezo feeder which would gently move the pins using micro-vibrations and a nonmagnetic base which offers significantly greater control on the feeding stage. This allowed the Micro Piezo feeder to successfully feed pins very quickly into a sliding escapement that delivered the pins to the installation location. With the new Micro Piezo feeder, Weber Screwdriving Systems Inc. is now capable of feeding micro fasteners with greater control and accuracy than our other feeding methods. These are parts and fasteners which are difficult for even a human operator to use due to their small size and handling limitations. To learn more about Weber’s Piezo Micro technology, please visit our website at www.weberusa.com. Weber Screwdriving Systems Inc. 1401 Front Street Yorktown Heights New York 10598 Email: [email protected] www.weberusa.com Tel: 914-962-5775 Fax: 914-962-5321 68 ASSEMBLY / February 2012 www.assemblymag.com

Matica Solutions Help Northrup Grumman Serve US Navy

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atica System offers an extraordinary portfolio of solutions that enable end users of metal plate and tagging hardware to fulfill a multitude of applications from Automotive VIN Plates to Military IDs to Cabling Tags to Appliance Serial Number Plates, and more. The Matica line of industrial marking solutions has been a world-wide leader for over twenty years with a customer list that reads like a “who’s who” of fortune 500 manufacturers, including GE, Ford, Boeing, Lockheed Martin and General Dynamics. Recently, Matica solutions were supplied to Northrup Grumman through Data Technology Systems to assist in their product identification needs for materials used on US Navy warships. The Matica C410 metal plate embossers were modified to accept Teflon coated tags that are special to Northrup’s application. These tags are embossed, separated and then affixed to individual cables and spare parts to track them from manufacture to warehousing to installation on Navy vessels. The durability of the coated metal tags under conditions of extreme moisture, temperature and wear gives them an advantage over legacy paper and plastic tags. In some cases, painting is required to assist in visual identification, so the Teflon is removed so the human readable embossing is more legible. Since their installation in mid-2011, Northrup has produced hundreds of thousands of custom Teflon tags on just two Matica C410s. This proven solution can be integrated with auto-feeders for even faster production, offers a wide variety of character sets, and has the ability to produce both 2D and standard barcodes. Digital Identification Solutions / Matica System 111 Kiowa Lane Piedmont, SC 29673 USA Phone: 864-272-1199 Fax: 864-751-2855 mailto:[email protected] http://www.matica.us

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ith a customer looking for significantly faster production, a major integrator decided to develop a dynamic container flow system. Frustrated with the cost, complexity and problems with trying to create a PLC solution, senior management decided to look for a better alternative. The requirements for the new system were extensive: significantly improve operator throughput, control conveyors and ASRS in real-time, contain advanced business logic, coordinate & error-proof pick requirements, seamlessly integrate to ERP/MRP, be easily setup & modified, report results in a browser’s web-page, use existing hardware, and support other plant floor devices. After carefully considering several options, Tutelar Technologies’ Ujigami™ system was selected. The power and flexibility of Ujigami provides an advanced graphical operator interface, advanced real-time production decisions, and permits the PLC to concentrate on fewer control tasks. Tutelar Technologies worked directly with the integrator to create a comprehensive plant-floor solution. Total development time was 8 weeks. The integrator’s customer is enthusiastic about Ujigami. The system eliminates all order setup requirements and permits their operators to dedicate 100% of their time to production, resulting in a 22% productivity improvement. As a result of the outstanding success of the new line, the system will be installed in the company’s other plants. Visit www.watchover.us/faster to see a video of the system in action. Tutelar Technologies Inc. www.watchover.us Sales: (905) 331-6808x7401 (248) 237-4975 Covering all of North America.

A “Better Idea” Saves Money and Floor Space

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ur customer defined a need to reduce labor cost and floor space, and to provide a system that could easily accommodate future products. A “better idea” significantly reduced both cost and the floor space required by eliminating the need for a substantial pallet conveyor system, pallets and tooling. This equipment assembles a ball joint, bearing, circlip, dust cover, and serialized label to steering knuckles. The ability of the robot controller to allow the robot to be displaced by the ball joint press, while maintaining its grip on the work piece, makes this concept possible. A ball joint is singulated from a bulk feeder inline and placed to a tool under an air over oil press. The robot acquires a knuckle from locator pins in a Parts Washer that is integral to the system. Next, the robot locates the knuckle over the ball joint in the press. The press is cycled, moving the casting down over the ball joint. When the press cycle is complete, the robot transfers the assembly forward to the next process station without ever letting go of the part. Process variables including press force and distance are captured for process monitoring and stored for part history. We were able to provide our customer with a cost competitive and highly configurable system to reduce labor and space required, improve yields, and provide an assembly facility that will serve them well into the foreseeable future. Contact Xigent Automation Systems today to see if we have a “Better Idea” for you!

AUTOMATION SYSTEMS

8303 Green Meadows Drive N. Lewis Center, OH 43035 PH: 740-548-3700 www.xasinc.com www.assemblymag.com February 2012 / ASSE M B LY 69

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DE-STA-CO Provides Precise Control

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Innovative Ring Positioner – WEISS North America

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n Aerospace company had a light machining application requiring positional adjustment. The application involved rotating a chuck holding a nozzle about the size of a soda can. The nozzle is turned through a small angle and the position of the nozzle is mapped with a vision system. Feedback from the vision system allows final adjustments to the part location. Once properly located, the machining operation on the nozzle can begin. DE-STA-CO recommended a 115RSD Rotary Servo Drive. The 115RSD was well suited for this application with its large center-thru hole for feeding pneumatic or hydraulic lines to the chuck, adaptability to industry standard servo motors, and zero-backlash for precision control and flexibility.

DE-STA-CO, a Dover Company 1025 Doris Road Auburn Hills, MI 48326 888.DESTACO www.destaco.com [email protected]


DAG , a global supplier to the transportation industry, needed a solution for a new production concept. They envisioned a large, open center ring that allowed for the placement of a heavy-duty robot in the middle. The challenge was that it didn’t just need to have a large inner diameter but also needed to be able to bear the weight and inertia of car body parts and tools weighing more than 20 tons. According to EDAG there were no available heavyduty positioning rings available on the market capable of doing this task. Instead of designing and manufacturing their own solution they decided to partner with WEISS. WEISS, the world leader in indexing and positioning table technology, delivered a completely new solution in only six months. Within a short time WEISS developed a solution that could handle a vertical axial static force of 1000 kN on the dial plate, a central opening of two meters, and a freely programmable drive. The newest member of the CR family was naturally designed to inherit all the positive characteristics of its peers: a flat compact design, zero backlash, and an optimized power transmission. The overall height of only 300mm allowed for maximum ergonomic planning. This system combines the advantages of a classic rotary table with a shuttle system in which robots can access the work piece from both sides. This is only one combination of EDAG’s new Compact Flex production system. The WEISS solution offered a programmable table for total flexibility of the positioning angle. There was also an immediate cost savings realized by saving floor space brought on by the ability to mount large equipment in the center. Details on the WEISS CR index table line can be found at our website along with the full success story of the EDAG program. Weiss North America, Inc. 3860 Ben Hur Ave Willoughby, OH 44094 www.weissna.com 888-WEISSNA (934-7762)

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Design Tool Helps With “Oven Appliance Assembly”

Compliant Pin Pressing & Inspection

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esign Tool, Inc., DTI, helped a manufacturer of oven appliances reduce the labor costs and assembly time needed to produce their special-purpose ovens. Using the DTI 5000 Rigid pistolgrip automatic screw feeding and driving system, the operators were able to continue to use the screw to align the sheet metal parts of the oven together as they were doing prior to receiving the automatic screwfeeders. “The compact, lightweight design of the DTI 5000 pistol style tool really allowed the operators to keep their hands close to the work, which is a critical factor in making semi-automatic assembly operations efficient.” reported Tom Rougeux, Sales Manager for Design Tool. The automatic screwfeeders were significant in keeping loose screws from being dropped into the oven assembly, which resulted in more frequent customer complaints and rework. Fastening cycle times were reduced from 8 seconds to 3 and daily production numbers were up nearly 20% after only three weeks of use. “We fully expect the customer to be realizing 30% faster cycle times once the line gets balanced and the operators have a consistent product flow. Once they develop new ‘muscle memory’ as a result of consistency, the efficiency numbers will rise again.” say Rougeux. The Rigid feature of the DTI 5000 system holds the screw firmly in the nosepiece assembly by the bit. The Rigid allows the operators to “feel” the assembly being aligned and assists the operator in the efficient assembly of sheet metal and other parts that need to be aligned before assembly. An overhead balancer system is used to hold the pistol tool over the assembly line ready for operation when the oven is presented to the operator. Design Tool, Inc., “DTI” manufactures custom, automatic screw feeding and driving systems for use in all industries. Design Tool Inc. 1607 Norfolk Place SW Conover, NC 28613 800 948 1038 Designtoolinc.com [email protected]

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o successfully press a printed circuit board (PCB) onto two 64 compliant pin connectors, SCHMIDT Technology designed and built a custom, self-contained assembly cell. The assembly process requires pressing the PCB to the bottom of the housing without damaging the board and ensuring that all pins have been pressed through to a specific height. A SCHMIDT® ServoPress 420 Module, which generates up to 4,400 lbs. of continuous force and features 100% in-process control and monitoring, performs the pressing operation. A SCHMIDT® PRC5000 controls the pressing operation and handles all process sequencing and positioning. At an auxiliary station attached to the press station, an operator scans the barcode on the PCB, prints a duplicate label and attaches it to the housing. Mylar foil and the PCB are then placed in the housing. A servo-controlled linear slide with nesting fixture transfers the workpiece to an integrated pre-press inspection station. There the system verifies the presence of the Mylar foil and determines whether all compliant pins are present and properly aligned. If pre-press inspection is OK, the workpiece advances to the press station for the final assembly process. During the press cycle, the ServoPress system presses the PCB to its final position. The system presses to a programmable distance to set the pin stick out and verifies the total pressing force applied to the pins. By monitoring pressing force and distance, the system confirms if the PCB is properly seated. If the press cycle is OK, the workpiece transfers to a post-press inspection station where the final height of each pin is measured and verified. If the part fails this inspection, it is returned to the operator. The SCHMIDT work cell features all-round guarding with ESD Lexan panels and single-hand cycle initiation via a light-touch button. SCHMIDT Technology Corporation Cranberry Corporate Center 280 Executive Drive Cranberry Twp., PA 16066-6415 724-772-4600 1-800-959-1218 www.schmidtpresses.com www.assemblymag.com February 2012 / ASSE M B LY 71

CASE STUDY

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CASE STUDY

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Nothing Stops An Assembly Line Faster Than An Injury But They Are Preventable.

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nfortunately, injuries are also very expensive. Insurance costs, such as workers compensation and other medical coverages keep increasing. The loss of production and time, the training of new personnel, the paper work for injury reports, etc., etc., all contribute to the reduction of profits. Our society has also become very litigious which also contributes to the higher costs of insurance and legal fees. These costs can be eliminated by providing safety tools and training. Every assembly line we have ever surveyed had opportunities for accidents and injuries. Fortunately we were able to provide tooling that not only eliminated those possibilities but also improved the morale of the workers and in many cases improved the production rate. It is music to our ears when the installers thank us for making their job sites safer and their jobs easier. By covering a socket and extension with free spinning sleeves and eliminating the pinch points that often snag a loose thread on a glove, we provide the employees with a new confidence in their tools and peace of mind. By providing our tools with methods that control the fasteners we eliminate the possibility of littering the work area with screws, bolts or nuts that can be stepped on and become a hazard. The neodymium magnets that we use in many of our tools along with unique mechanical devices for plastic and stainless steel fasteners, insures that we keep the work area safe. We are the “MUTILATION PREVENTION DOCTORS.” Let us prove we can cure your assembly headaches. Production Tool Company 9002 Dutton Drive Twinsburg, Ohio 44087-1931 330-425-4466 Fax: 330-425-1584 www.productiontoolco.com


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HYPERCYL-EMA actuator reduces Customer Costs and Down-Time Problem—A food grade paper tray manufacturer came to Aries/HyperCyl looking to save on monthly electricity expenditures and wanted pricing to replace (20) 30-Ton hydraulic presses. Current cylinders cost approximately $180,000 in electricity yearly, not including disposal fees of hydraulic fluid and maintenance fees. Solution—Using HyperCylEMA actuators provided a cost Savings to our customer in excess of $100,000 annually when compared to the hydraulic units previously used. Extreme Accuracy and Quality coupled with cost savings allows HyperCyl-EMA to compete with any electric or hydraulic cylinder on the market! The ability to apply force the entire length of the stroke makes HyperCyl-EMA widely suitable for use in applications such as Pressing, Stamping, Assembly line or Robot installations and other various high force/ highly accurate projects. HyperCyl currently provides high force solutions to many diverse industries such as Medical, DOD, Munitions manufacturing, Tier 1 automotive companies and Aerospace manufacturing. Standard equipment includes the Emerson UniMotor, Internally mounted temperature-compensated Load Cell, Standard Internal Non-Rotate and End of stroke Proximity sensors. Stroke lengths are 8.00” and 14.00” contact the factory for additional stroke availability. We can also offer the HyperView Press signature analysis controller with 10” TFT touch-screen for Live-Time Quality Control over your application while In-Process. These exceptionally accurate actuators (.0001”) have a high rate of repeatability and create a cost-effective alternative to hydraulic units as a result of their no fuss installation, limited maintenance schedule and user-controlled adjustability. Complete tooling-ready TurnKey presses, as well as standalone actuators are available upon request. Contact Aries Engineering/HyperCyl at 734/529-8855 or through our website, www.hypercyl.com, for more information.

Products Control System Has Multi-Axes Drive Module Now featuring a five-axis drive module, the NYCe4000 motion control system can drive several brushed or brushless motors in demanding applications. The module measures just 120 by 140 by 20 millimeters, and multiple modules can be combined in a single housing. PWM amplifiers in

Custom Laser Enclosures This company designs and installs Class 1 laser product and laser control area enclosures for machine integrators and manufacturers. The enclosures protect against UV, near infrared, far infrared and visible light. Offerings range from tabletop to room-size robotic enclosures. All enclosures are tested and FDA certified to 21 CFR 1040, ANSI Z 136 and EN 60825-4. Each project is managed by a certified laser safety officer. If required, enclosure assembly can be done on-site. RT Technologies Inc. www.rtlasersafety.com 770-332-0092

High-Frequency RFID System

the module have a power range up to 70 watts. The module lets users connect a variety of encoder types to the same physical interface. It also has an integrated I/O. Bosch Rexroth AG www.boschrexroth-us.com 800-739-7684

This RFID system operates on a high-frequency wavelength (13.56 megahertz) and can integrate all RFID tags that comply with the ISO-IEC 15693 standard. Because its read and write modules can be connected directly to an RS485 fieldbus, a network of up to 253 modules may be created. With a USB adaptor, up to 10 modules can be directly addressed physically from a control console. A selector built into the device determines the module’s physical address. Contrinex Inc. www.contrinex.com 860-388-3573


Products Forklift AGV

OPTIMIZE THROUGH AUTOMATION Discover all the potential now: At AUTOMATICA 2012.

The operator of this forklift AGV can either drive the vehicle manually or run it in fully automatic laser guidance mode. In either mode, the forklift performs many types of stacking, including deep lane floor, pushback, drive-in and standard. Two models are available, with 3,500- or 5,500-pound lifting capacities. The forklifts have a lifting height up to 23 feet and are powered by industrial lead-acid batteries. They feature a touch screen monitor and run Windows. Egemin Automation Inc. www.egeminusa.com 616-393-0101

Inspection System With Magnification Visitors to this month’s MD&M West show can see the Tagarno Magnus HD Trend inspection

system designed for manual product assembly, repair, quality control, noncontact 2D measurements and data capture. The system’s camera head can magnify an object up to 320 times and display it on any size screen with HD image quality. The camera head can be rotated 90 degrees and tilted 45 degrees, allowing the operator to inspect at various angles. Christopher Associates Inc. www.christopherweb.com 714-979-7500

Mobile Workstations MRO Workstations are high-density storage cabinets on wheels that let workers bring parts, tools, supplies and equipment to job sites, saving time and increasing productivity. Avail-

BLIND RIVETING’S SMART CHOICE ASSEMBLY AND HANDLING TECHMACHINE VISION NOLOGY POSITIONING SYSTEMS ROBOTICS SENSOR DRIVE TECHNOLOGY CONTROL SYSTEMS TECHNOLOGY SAFETY TECHTECHNOLOGY NOLOGY SUPPLY TECHNOLOGY

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“Speed, Precision, Power” HyperCyl-EMA (electro-mechanical actuator) A robust, servo driven actuator designed for precision assembly applications or applications not suited for standard HyperCyl hydra-pneumatic products.

able in various heights, widths and depths, the workstations feature built-in shelf storage behind a lockable door, and drawer storage to accommodate items of different shapes and sizes. Each cabinet drawer extends a full 100 percent from the housing and holds up to 440 pounds. An interlock safety system prevents accidental tipping. Lista International Corp. www.listabox.com 800-722-3020

Available in both roller screw and ball screw configurations in load ratings from 1-25 tons. Capable of .0025mm (.0001”) repeatability and up to 500mm/sec ram speeds. Optional HyperView-Press signature analysis controller available for improved finish product quality, substantially reducing manufacturing costs. Contact us for details, options, packages and solutions.

Quick-Disconnect Cord Sets QDS electrical quick-disconnect cord sets facilitate quick, easy and safe connection of the company’s digital vacuum switches and sensors to system controllers, PLCs

Electro-Mechanical Actuators 130 Aries Drive, Dundee, MI 48131

734.529.8855

Fax 734.529.8844

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Complex components need reliable protection. and other extension connectors. The cord sets’ screw-plug connection makes them a low-cost alternative to labor-intensive joining and soldering wires together for robotics, automated assembly equipment and heavy-duty industrial environments. Three-, four- and five-pin male and female cordsets feature M8 or M12 threading or threaded couplings for easy field conversion. Cordsets are RoHS compliant. Vaccon Co. Inc. www.vaccon.com 508-359-7200

Brake System for Linear Guides A carriage brake system is now available on UtiliTrak linear guides. This system is a two-component assembly that manually secures a carriage to the rail in confined spaces. Brake system components are made of anodized aluminum and positioned below the carriage’s payload mounting surface to

When you need to precisely spray and dispense liquid coatings, the SCS Precisioncoat selective spray and dispense coating system provides maximum accuracy and flexibility. The system applies 100% solids, solvent-based and water-based coatings via three to five axes. Optional features, such as needle calibration, vision system, offline programming and barcode reader capability, meet any production requirement. SCS Precisioncoat systems connect seamlessly with SCS thermal and UV cure units, enabling components to move from coating to curing without operator intervention. Contact SCS to find out more about our innovative solutions for your advanced technologies. World Headquarters (US): 317.244.1200 www.scsequip.com


Products Force Measurement and Material Test Systems Digital Force Gauges

LS1

The DFX II, DFE II and DFS II span the full range of handheld and stand-mounted force gauge applications from the simplest “Go-No Go” to the most sophisticated quality control.

A 1 KN/225 lbf high precision materials testing machine that combined with our extensive range of grips, fixtures, extensometeres and software creates a powerful system.

Bluetooth communication and full-color displays are among the new features.

minimize interference. The angular position of the handle arm adjusts to any position without affecting brake engagement or braking force. The brake system can be factory preassembled on new systems or retrofitted. Bishop-Wisecarver Corp. www.bwc.com 925-439-8272

Reworkable Adhesive for Ball Grid Arrays

Phone: 727-538-6000 Toll free: 800-527-9999 www.chatillon.com

UA-2605 is a reworkable edge-bond adhesive that improves thermal cycle performance of ceramic and plastic ball grid arrays, which sometimes need to be reballed during PCB assembly. The adhesive also eliminates the need for underfill and is easier to apply. Underfill requires the PCB to be preheated and adhesive to be dispensed in multiple passes. UA-2605 requires no preheating of the board or multiple passes— just four beads of adhesive, one dispensed in each corner. Zymet Inc. www.zymet.com 973-428-5245

See us at ATX Texas, Booth 729

The material matters in material handling

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*VTWVZP[P]LSÌL[[LY Widest range of composite nest and stack containers Lids protect parts from dirt and damage Optional dollies for easy transport Reinforced composites bring a whole new level of performance to processing and material handling. And the leading name in FRP is MFG. Contact your local distributor or call (800) 458-6050. Learn more about Toteline™ at www.mfgtray.com. 463+,+-0),9.3(::;9(@ 9V\[L3PULZ]PSSL7(

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Slot Manager January-February 2012

Site Prep January-February 2012

Food & Beverage Packaging January-February 2012

Paint & Coatings Industry February 2012

Assembly February 2012

Appliance Design February 2012

SNIPS February 2012

Casino Journal February 2012

Security February 2012

iCleaning Specialist February 2012

Engineered Systems February 2012

Quality February 2012

Roofing Contractor February 2012

FORGE February 2012

ISHN February 2012

Stone World February 2012

National Driller February 2012

HAPPI February 2012

DesignNews Magazine February 2012

Supply House February 2012

World Trade February 2012

Prepared Foods February 2012

Ceramic Industry February 2012

Pollution Engineering February 2012

Flexible Packaging January-February 2012

National Floor Trends February 2012

Environmental Design + Construction February 2012

Slot Manager January-February 2012

Mission Critical January-February 2012

Plumbing Mechanical Engineer February 2012

25 Beautiful Homes - February 2012

Slot Manager January-February 2012

Site Prep January-February 2012

Food & Beverage Packaging January-February 2012

Paint & Coatings Industry February 2012

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