ROBOTIC SOLUTIONS
RoSI
Robotic Seal Inserter
RoSI is designed to insert blind seals and/or hard pins into connectors in a fast, fully automatic and controlled way.
It has a rotating working area with 2 trays where the operator puts the connectors after selecting the production order, i.e. the connector, the insertion pattern and the quantity to produce.
The workstation rotates the tray inside and the robot automatically picks up the needed insertion tool and the insertion process begins, with the seal feeder shooting the seals to the head of the robot and then into the connector’s via.
It can work with up to 4 seal feeders, which allows up to 4 different seals per connectors. The entire process is done automatically and at the end, a vision system will inspect the insertion process.
Can also be supplied with an automatic connecotrs feeding system, for increased automation and autonomy.
RPM Vision +
Robotic Punching Machine with Vision Inspection
A robotic system designed to break plastic pins from connectors (punching system) in a fast and automatic way.
It has an integrated vision system to inspect and validate the end results of the punching process.
It has dedicated tools for each vias’ pattern and allows the processing of different connectors, in the same operation.
The standard machine can handle 8 different connectors with 8 different punching tools.
After selecting the pattern with a barcode reader or a network file (KSK server), the operator puts the connectors in the selected nests. The machine will pick the necessary tool and angle and start the punching process.
At the end of the process, the vision system will check each of the connectors to ensure that the punching process is accurate and burr free, identifying OK and NOK parts.
RPM
Robotic Punching Machine
The RPM is a robotic system designed to break plastic pins from connectors (punching system) in a fast and automatic way.
It ensures high quality and precise results with burr free cut and undamaged connector’s vias. It has dedicated tools for each vias’ pattern, but the operator just needs to put the connector in the selected nest, since the punching pattern is selected using a barcode reader or a network file (KSK server) and the automatic tool replacement system selects the necessary tool. It allows the processing of different connectors. Combined with this flexibility, it also has a high productivity, with an average cycle of 0.7 second per pin.
RoCAM
Robotic Connector Assembly Machine
The RoCAM is designed to assembly mini connectors in a fast and flexible way, allowing to change parts to be assembled without need for hardware modifications.
Its uses 2 flexible feeders, that use vision systems to detect the orientation of the parts and 2 Scara robots that pick up the parts and assembly them in a flexible conveyor.
It performs the OK/NOK parts checking using a vision system, automatically sorting the assembled parts to the respective storage.
It includes force and position control to perform the assembly.
Keeping almost the same speed of assembly when comparing with hardware dedicated assembly machines, it allows to use the same machine in different configurations and, more importantly, in new connectors just changing software.
CRAE
Connector Robotic Assembly Equipment
CRAE is a semi-automatic robotic system designed to assembly connector parts.
It has the capacity to assemble 3 different sets and it handles all its distinct components (rubber, plastic, etc), using always the same hardware.
It has rotating trays in order to ensure nonstop production, allowing the machine to operate in one side of the trays, while the operator is loading or unloading components on the other side.
A vision system is used to detect the components, their orientation and to perform the final visual inspection; an electric clamp with force sensor is used to pick up the components and a load cell is used to measure the insertion force.
The system is a perfect example of combining robotics with vision systems in order to automate delicate and complex tasks, providing flexibility and ensuring 100% quality.
By using vision systems and components with high flexibility, instead of the traditional probes and pins used in tight tolerance jigs, a practically maintenance free machine is obtained and ready to be adapted to other assemblies without the need of reworking the entire machine.
AFRA - Automatic Fuse and Relay Assembly
The Automatic Fuse and Relay Assembly (AFRA), is a complete and fully automatic assembly line designed to assembly screws, fuses and relays into fuse boxes that are already mounted into the wire harnesses.
The number and disposition of the stations are solely dependent on the output desired, since the stations are completely modular and can be arranged in any given order or topology, even being able to work in standalone mode, if desired.
The complete wire harnesses, already packed, are carried out through the conveyor line using trolleys.
Before entering the line, the operator scans a barcode that tags the harness and communicates with the central server in order to acquire the insertion pattern. This associates the trolley to the harness and to the desired insertion pattern.
This allows that each harness moving along the line can have distinct insertion patterns.
After entering the line, the process of assembly and final test is fully automatic and without human intervention.
AFRA - Screw Station
The AFRA – Screw Station, is a fully automatic system designed to screw nuts into fuse boxes which are already mounted into wire harnesses.
The screw station is one of the modular stations of the AFRA assembly line, but it can also work as a standalone station.
It has a SCARA robot, with an electric screwdriver, that screws a nut in a specific location of the fuse box.
It has a bowl feeder that automatically feeds and delivers the nuts into the head of the electric screwdriver.
The nut is supplied by a bowl feeder that shoots the nut into the head of the robot.
Before the screwing process, the machine detects if the cable shoe is present or not.
The screw process is fully compliant with the VDI2862 Category A norm, with double redundant check systems to monitor and verify the torque and angle of the screw spindle.
For each screw cycle, the tightening curve is recorded and stored for traceability.
AFRA - Fuse Insertion Station
The AFRA – Fuse Station, is a fully automatic system designed to insert fuses into fuse boxes that are already mounted into wire harnesses.
The fuse station is one of the modular stations of the AFRA assembly line, but it can also work as a standalone station.
The fuses are inserted by a SCARA robot, at a rate of one fuse each 2 seconds, using a clamp with a load cell.
The fuses are picked up in a fixed position at the end of a linear guide, delivered through several different bowl feeders, one per each fuse type.
The load cell monitors continuously the insertion process and is also used to detect any problem that might occur during insertion, namely: no insertion force, closed contacts or rear plugging.
For all positions, the insertion force is recorded and stored. The positions that originate an error are automatically marked and signaled to the central station, to mark the harness for rework.
AFRA - Relay Insertion Station
The AFRA – Relay Station, is a fully automatic system designed to insert relays into fuse boxes that are already mounted into wire harnesses.
The relay station is one of the modular stations of the AFRA assembly line, but it can also work as a standalone station.
The relays can be supplied in trays or tubes, depending on how they are delivered by the manufacturer.
A SCARA robot will pick up the relays one by one and insert them into the desired position, at a rate of one relay each 2 seconds.
The robot has a clamp, equipped with a load cell that monitors continuously the insertion process and is used to detect any problem that might occur during insertion, like: no insertion force, closed contacts or rear plugging.
For all positions, the insertion force is recorded and stored and any position that originates an error is automatically marked and signaled to the central station, to mark the harness for rework.
AFRA - Vision Inspection Station
The AFRA – Vision Station, is a vision inspection system designed to verify if the fuses and relays assembled into fuse boxes are in accordance with the desired.
The vision station is one of the modular stations of the AFRA assembly line, but it can also work as a standalone station.
The fuse boxes are already mounted into the wire harnesses. So, the full harness is brought to the vision station through trolleys by an operator (in standalone mode) or by the AFRA conveyor (in production line mode).
The vision station not only verifies if the components are present or missing, but it also verifies if they are on the right position, if they are the correct ones and also their orientation and height.
After the test, the vision station will inform if all components are well assembled or, in case of an error, identify which positions are incorrect.