#Product Trends
User report. Assembly, transfer and test systems for different toothed belt components
When everything flows and inter-locks
A producer of toothed gears and gears relies on an assembly, transfer and testing sys-tem by IEF-Werner for the production of different components. The automation spe-cialist provides all systems like the palletisers for supplying single parts from in-house production. The user does not only reach very high cycle speed with the complete line but also a very high degree of safety of quality – without having to deploy staff. The basis of the assembly plant is the conveyor belt system posyART. Due to its modular construction new process stations can be integrated into the plant or replace consisting ones at any time.
Furtwangen, 01.07.2016 – When looking at some assembly lines one imagines an engineer designing with an ink drawing pen between the fingers on a drawing board. Probably with the left eye brow raised up, a focused view and the mouth slightly opened, similar to a watch maker; as the single plants work together just as precisely as a Swiss clockwork. One step follows exactly on the next, just like in a gear box where one toothed wheel interlocks with the other. Between the steps no useless second. “Even though this as-sembly and testing line was not developed at the drawing board, it was still designed with much care and passion for details”, Oliver Koch, product manager at IEF-Werner. The demands of the customer were high and special. The plant assembles different toothed belt components for motors. Depending on the type they consist of two equal or different spur gears, a snap ring as well as an angular ball bearing or a tension spring. Meanwhile the plant tests before, during and after the assembly process the critical quality features of the parts. “This is how we allow a 100 percent test – all automatically”, Oliver Koch emphasiz-es. “The user does not have to provide any staff for this task and can be absolutely sure that every as-sembled component confirms the high quality standards.”
Until the end of the year, around 100.000 components of every toothed belt type should be produced; 2019 up to 700.000 a year. “For this, the plant not only has to be very efficient but also flexibly expanda-ble,” Oliver Koch explains. IEF delivers the complete line from one source – including software and con-trolling technique.
Conveyor technology from the construction kit
The plant assembles the components fully automatically. Especially the technical availability was important for the manufacturer. This should not fall below 95 percent. The extendible conveyor belt system posyART forms the basis of the assembly plant. The reliable, flexible and precise modular system contains many standard components, which help to solve almost every task in transfer, assembly or the logistics sector. The main components such as strap, drive, turnouts or stopper are very long lasting. The dovetail geome-try at the long side of the profiles allows to position all mentioned components precisely and continuously. “We equipped the system with work piece carriers and the corresponding intakes”, Oliver Koch illustrates. Depending on the use, work piece carriers are brought into the right position by means of lateral position-ing, centring station or the rotary lifting station. In the centring station for example they are positioned centrically and subsequently fixated three dimensionally with an accuracy of +/- 0,05 millimetres. The stoppers are arranged centrally. That prevents the work piece carriers from tilting in the guide rails. Four intakes for two toothed wheels in each case are located on the work piece carriers for this use. Each carri-er contains a RFID code, which submits the status of the components and the data to a superordinate control.
The palletising systems type varioSTACK are placed at the beginning of the line. The very compact pallet-isers can be loaded frontally by default with transport belts or transport trolleys. “We conceptualized the machines for this use, so that the integrated product handling is able to extract components out of grid baskets from the costumer”, Oliver Koch explains. The grid baskets are fixed and made available to be loaded automatically. The palletisers place the four spur gears one after the other on the first work piece carrier within a few seconds.
Are the internal and external dimensions of the toothed wheels correct? Are the edges sanded? In order to get these answers, the work piece carrier approaches a measuring station. The handling takes two com-ponents each time and deposits them as a pair in the right position. The measuring process starts. A screen at the station shows the results, the data is saved. This process is repeated with the next two com-ponents. Subsequently the plant submits the value to the control. Depending on the component type the carrier proceeds with the wheels to the next process step: either an angular ball bearing or a tension spring is installed. After that every component is equipped with a snap ring.
Different inspection methods
After the assembly, the line conducts different inspections at the components. For example the torque of the two differential gears has to be determined. If the result is not conform with a predefined value, which is adjustable by the costumer, the part is put on N.O.K. (not correct). During the twist inspection, a pick up device drives onto the respective component and twists tension and main wheel to each other.
The measurement of the output is conducted via torque measurement. If the system detects stiff positions and if these exceed a defined value, the component`s status is put on N.O.K. Generally the plant does not further manufacture parts or components with the status N.O.K.
After the inspections the work piece carrier is lifted via a lift and turning device and is turned 180 degrees. The work piece carrier positions them in this location under a laser, which applies the respective label. A camera system controls the type face and tests the included data on their plausibility.
In order to withdraw the completely assembled components, IEF delivers a further varioSTACK conveyor belt system. At the plant an employee puts empty small load carriers (SLC) by the pile on the conveyor belt. “He pays attention to the correct position of the inlets and lids of the containers”, Oliver Koch ex-plains. The pile runs automatically into the palletiser. The upmost SLC is singled out and put on the pallet-iser table. A suction gripper extracts the lid and parks it on the pallet table. Subsequently the table goes together with the SLC under the Z unit with gripper. This withdraws all inlets but the lowest. The SLC goes into the loading position. The palletiser extracts the component out of the work piece carrier. “If they are coded with N.O.K., the components are sorted into four categories and then put on a discharge belt”, Koch describes. The parts marked with O.K. arrive at the mould cavity of the inlets in the SLC container: as soon as the first inlet is full, a suction gripper extracts a VCI-cutting out of the buffer and puts it on the filled tray. The next inlet is put on top of that. When the SLC is completely filled, the suction gripper with-draws the lid and closes the SLC. The completely loaded and closed SLC are now put on the discharge belt by the pile. The special feature: the packed components do not have to be measured again. The IEF plant ensures the demanded quality.
Oliver Koch is very content with the realisation of the customer demands. “Every component of this plant interlocks smoothly with the others, exactly like the toothed wheels, that are produced by this plant.” With this the user reaches very high cycle times and a high quality safety and is ideally prepared with the po-syART system for future expansions.
