Assembly automation – assembly and testing system for ball valves with a wide variety of parts

Workpiece:

Ball valves in different versions

Task:

Development and construction of a system for the fully automated assembly, testing and marking of ball valves in various variations as well as an adjacent, partially automated assembly and packaging station.

Solution:

In a fully automated system, previously assembled ball valve housing units are stamped and tested for internal and external leaks in a leak testing station. Good parts are marked using a laser process, reject parts are ejected. Four leak test stations are installed in parallel to increase the cycle time.

After subsequent, fully automatic O-ring assembly, the presence and correct fit of the O-rings are monitored with a camera inspection. Good parts are marked by means of pad printing, reject parts are ejected.

A modular design and conversion kits make it possible to convert to different variants in a short space of time.

At an adjacent, semi-automated workstation for the manual assembly of small parts, the housing units are completed and packed with various small parts to form finished assemblies. The workstation is ergonomically designed and height-adjustable.

Customer benefits:

• Fully automated testing and assembly area with embossing unit, 4 leak testing stations, laser marking, O-ring assembly and camera testing
• High level of operator safety thanks to closed cell with safety doors
• Good visibility for operating personnel through large windows
• Short amortization time due to adapted degree of automation and use of standard products from the TECHTORY automation kit
• Semi-automated final assembly and packaging station with high functionality: monitored screw-in process and additional camera monitoring
• High ergonomics: height-adjustable work areas, easy-to-grip provision of small parts, reduced assembly times due to short gripping distances