Semi-automated manual workstations – Assembly and testing system for a fresh air grill

Workpiece:

Fresh air grill consisting of housing parts, louvres and other components

Task:

A semi-automated assembly of fresh air grills for motor vehicles with final quality control is to be carried out at several successive workstations.

Solution:

Three semi-automated workstations and a final test station were connected to form an assembly line. Workstation 1 consists of two stations with protective covers for the semi-automated assembly of various O-slats. Assembly can be carried out independently of each other at both stations. At workstation 2, the components are inserted into drawers. After insertion, the drawer is secured for the rest of the process. A punching tool cuts off the sprue of the H-slats. A Scara robot removes the H-slats from the tool and places them in an assembly device. Here, the slat pack is assembled and ejected by the robot. Workstation 3 is a purely manual workstation where the slat packs are pressed into the housing. The insertion positions are also monitored here.

In a final EOL test station, a functional and completeness check of the installed components is carried out; O.K. parts receive a label.

Customer benefits:

• Partial automation with high functionality and process reliability
• Ergonomic operation, design based on the poka-yoke principle and high safety standards
• Signal lights to indicate correctly inserted components
• Short payback time due to individually adapted degree of automation
• Integrated quality control through EOL test station