ASM INDUSTRIES

Robots Perform Quality Control Role

A.S.M. Industries manufactures products for the Automotive Industry, including car alarm components exported to European markets by it's customer Robert Bosch (Australia) Pty Ltd, for use by companies such as Opel, Volvo and Audi. To assist in this program, A.S.M. Industries are using a robot at their Clayton, Victoria manufacturing site to ensure the highest possible quality standards are maintained in its manufacturing process.

As a leader in plastic component manufacturing for many industries including the demanding automotive industry, A.S.M. Industries perform rigorous testing procedures under their ISO9002 quality program. Utilising robot technology as an integral part of this process ensures testing procedures are duplicated exactly each and every time they are performed. A.S.M. Industries recognise this as one of the primary benefits with robotics; robots perform exactly the same role over and over again without the variables introduced by operators.

With the prohibitive price of dedicated testing machines, A.S.M. Industries approached Robotic Automation Pty Ltd with an idea to work with them to incorporate robot technology into the quality control and testing procedure for a car alarm siren they manufacture. With production which could exceed 400,000 units a year, A.S.M. Industries required a high speed, flexible solution.

The final solution involved a Motoman SV3 robot being interfaced with a personal computer, a barcode label printer, an ultrasonic welder, a leak test instrument, a sound level meter and barcode readers.

An operator loads 2 components into a fixture where they are clamped and moved into the robot cell. An ultrasonic welder is used to join the plastic components together. When this is completed, the robot picks up the unit and moves it to the barcode printer where the PC generated label is applied. The siren is then moved by the robot to a barcode reader for verification.

If no label is detected, the siren is placed into the "no label" reject shute. If the label is detected, the siren is placed into the fixture, clamped and leak tested. Because the leak tester has the longest cycle, Robotic Automation have programmed the Motoman robot to return to the start and begin the process again with new components. This ensures production occurs as rapidly as possible and all machinery is constantly in use.

If the car alarm siren passes the leak test, it then undergoes a sound test. Providing the siren passes both tests, it is deemed to have successfully passed the quality control procedure and is placed in a shute and presented to the operator. If the unit fails any of these critical tests, the unit is stamped with an "R" and placed in a reject shute.

The data acquisition software used in this process was written by Robotic Automation. It combines the Visual Operator Interface software (VOI) and the automated process. One operator can monitor the entire production process. A.S.M. Industries have been able to drastically reduce their cycle time from approximately 3 minutes per siren to 30 seconds per siren through the use of robotics and associated technology. The eventual aim is to reduce cycle time to around 20 seconds per unit.

Robotic Automation are leaders in robotic technology. Through their close association with Motoman Robotics, Robotic Automation offer a complete turnkey service from their extensive resources; site evaluation, design, supply of all automation equipment, installation, commissioning, operator training, and after sales support.

USING JET OF WATER TO CUT INSULATORS

With the contract to supply all firewall insulators for Ford and Toyota vehicles manufactured in Australia, Bostik rely on robotic technology to meet this huge requirement of over 180,000 insulators each year. The insulators are made and supplied under the "Just in Time" practice, requiring extreme flexibility to cope with the varying mixture of model types.

At their highly innovative manufacturing plant in Thomastown Victoria, Bostik use 2 cells supplied by Robotic Automation for waterjet cutting of firewall insulators. Each cell contains 2 Motoman SK16 robots operating in conjunction with a 6 station-rotating carousel, running 24 hours a day, 6 days a week.

Continuous Operation
Laminated insulator castings are manually loaded into 2 location nests outside each soundproof cell. While the robots are cutting 2 previously loaded blanks inside each cell, completed insulators are unloaded from the remaining 2 stations. This carousel arrangement ensures the robots are operating continuously, giving maximum output.

With the first cell containing 2 Motoman robots, carousel and safety enclosure installed over 3 years ago, Bostik had no hesitation in choosing Motoman robots from Robotic Automation when they needed another cell to meet increased demand. In both investments, engineers from Robotic Automation worked closely with Bostik to design and supply a turnkey robotic system that would meet their current needs and include room for expansion.

Flexibility
Flexibility is the key to the success of the robots. Continual improvement by both Bostik and the automobile manufacturers necessitates change; the ease and speed of reprogramming the Motoman robots enables enhancements to parts "on the run" and at far less cost than conventional tooling changes.

Very fine jets of water at high speed are used to actually cut the insulators, with the robot head programmed to move along a required path to an accuracy of less than 0.1 mm. The result is insulating cut to meet exacting specifications; consistently, accurately and repeatedly.

Bostik are a leading manufacturer and supplier of a range of products to automotive industries around the world, including Australia.

Robotic Automation are leaders in robotic technology and offer a complete turnkey service; site evaluation, design, supply of all automation equipment, installation, commissioning, operator training, and after sales support.

FROM CAULDRONS TO COMMODORES

Based in suburban Sydney and founded in 1919, toolmakers and metal pressing specialists G.A. & L. Harrington Pty Ltd have been involved in manufacturing many products including the cauldrons and torches used in the Olympic Torch Relay and the Paralympic Torch Relay.

Harrington's are also involved in the manufacture of another Australian legend, with the awarding of the VX Commodore B pillar reinforcement project by Holden. As part of the chassis of each Commodore, the B pillar separates the front and rear windows on each side of the vehicle.

Production Increase
Long term users of robots for arc welding, Harrington's have received over 10 years of reliable and efficient service from 2 OTC robots. Engineering Director Mark Bennett was so impressed with the reliability of these robots, he did not hesitate to invest in another 2 OTC robots from Robotic Automation when the company needed to increase their production capacity to service the VX Commodore contract.

High volumes, 500 B pillars per day, and the need for consistent accuracy in strong welds meant robotic welding was the only option for Harrington's.

With tight specifications and quality essential in the automotive industry, the OTC DR4000 offers position repeatability and accuracy to less than 0.1 mm. And the flexibility and ease of programming the OTC DR4000 means it can easily be used for other contracts when required.

The DR4000 from OTC comes as a complete welding package including a 6 axis robot manipulator DR controller, large LCD teach pendant, 350 or 500 amp welding power source, wire feed system and robot welding torch stop start stations. The whole package arrives ready to start welding without the need for interfacing.

The DR4000 is a compact and space saving design, with a 46% reduction of installation space compared with previous models and a wide working envelope. The advanced servo control system and lightweight body results in faster robot motion.

Robotic Automation are leaders in robotic technology and offer a complete turnkey service; site evaluation, design, supply of all automation equipment, installation, commissioning, operator training, and after sales support.