Automated Rotary Assembly & Test System for Oil Pump Lever Assemblies
Machine supplied: Fully Automated Rotary Assembly Solution
Client: Leading Power Transmission Component Manufacturer.
Part: Oil Pump Lever Assembly
Overview: This automated rotary assembly system was designed and manufactured to give the customer the ability to automatically assembly oil pump lever assemblies at a rate of 720 per hour. TQC developed this system alongside the client to allow them to supply quality, assembled parts to their customers.
To meet the throughput requirements 2 assemblies are built at the same time using a 4-station indexing rotary table system. This rotary table allows the sequential assembly of 3 components at a rate of 2 assemblies every 10 seconds. Localised part checking is included at each station with final parts fed out onto a conveyor (passed parts) or rejected (failed parts).
Multiple Stations located around an automated rotary assembly system with 4 stations to carry out the following –
- Station 1 Spring Load
- Station 2 Lever Shoe Load
- Station 3 Stopper Pin Load & Insertion
- Station 4 Assembly unload – passed and failed parts
Station 1 of this automated rotary assembly system
Springs are automatically fed in pairs using bulk storage, a linear conveyor, and a vibratory bowl feeder. Good springs are transferred to nests on a rotary table, while rejects are separated and discarded via a reject chute.
Station 2 of this automated rotary assembly system
Lever shoes are fed in pairs from bulk storage and a vibratory bowl feeder. Good parts are placed onto a rotary table; rejects are removed via a reject chute
Station 3 of this automated rotary assembly system
Stopper pins are fed via a twin-track vibratory bowl feeder and picked in pairs by a transfer unit. Length is checked before placing correct pins into rotary table nests; rejects are dropped via a chute. Lever/spring assemblies are clamped and exercised to align the pin hole for assembly. Any assembly failures are flagged and rejected at the off-load station
Station 4 of this automated rotary assembly system
At the final station, assembled products are removed from the rotary table. Passed parts are placed onto a conveyor; failed parts go to a reject chute. A twin-head gripper on a programmable gantry transfers assemblies, placing them in two rows of eight per cycle. The conveyor indexes after each set and can buffer around 20 minutes of production. A sensor stops the machine when full, and a jog function allows clearing of remaining parts
Control System
The assembly and test system is controlled via an Omron PLC and HMI.
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Automated Rotary Assembly & Test System
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