Turnkey Robotic Assembly Line for a Major Appliance Manufacturer (Case Study 5944)
The Challenge:
A major appliance manufacturer contracted us to provide a complete, turnkey floor conveyor and automation system. The project required a ground-up solution to build a new assembly line capable of producing multiple complex products. The primary goals were to integrate extensive robotic automation, develop a sophisticated conveyance network, and ensure the highest standards of production efficiency and operator safety.
Our Integrated Solution:
We delivered a comprehensive, fully integrated assembly line, managing all aspects from engineering and fabrication to installation and commissioning.
Robotic Automation: We deployed seven new robotic cells along the main assembly line. The Yaskawa-Motoman robots perform a variety of precision tasks, including:
•Pick and Place of key components from continuous running overhead conveyor directly to main assembly line
•Pick and Place of critical parts from subassembly systems to main assembly line
•Upending and Rotation of partially-assembled products to re-orient for better ergonomics and assembly functionality
We engineered custom End-of-Arm Tooling (EOAT) for each application, using technologies like actuated magnets, prick pins, and vacuum cups. Every robotic cell was surrounded by a complete safety system, featuring guard fencing, interlocked access gates, and light curtains for product entry and exit points.
Advanced Conveyance: Our team engineered and installed a complex floor conveyor system to move products seamlessly through the assembly process. This network included a wide array of equipment such as:
• Modular belt and roller bed belt conveyors for assembly stages.
• Powered turntables to rotate units 180-degrees between processes.
• A Continuous Vertical Conveyor (CVC) to transport products to an overhead test loop.
• A dedicated overhead conveyor loop for the functional test area.
Controls and Systems Integration: A new, facility-wide control system was designed and implemented to orchestrate the entire line. The system is controlled by an Allen-Bradley ControlLogix® Safety PLC. We installed multiple HMI operator stations for diagnostics and control, along with numerous remote VFD panels to power the conveyor system. For quality assurance and status monitoring, we integrated several machine vision systems, bar code scanners, and a comprehensive ANDON system featuring large-screen TV displays programmed with Ignition® software.
Turnkey Services: As the prime contractor for this turnkey project, our scope included all mechanical and electrical installation. We fabricated and erected numerous custom structures, including a large control cabinet mezzanine, multiple operator platforms, and over 500 feet of overhead tool rail to support manual operations. Our engineering team provided extensive on-site support through system debug, testing, and production startup to ensure a successful launch.