An industry leader in industrial electrical infrastructure solutions needed a machine to optimize the production of two kinds of jack modules. This project called for precision label application, or the application of a foil shielding strip to a jack module to be used in an industrial electrical environment with robotic assembly automation.
Since these jacks were meant for use in environments with high electrical activity, foil shielding strip application had to be spot on. Vision inspection with critical pass/fail points needed to be implemented so this product could make it to the next step in the production line.
High-speed motion to streamline this process was solved with robotic integration. By setting coordinates and highly precise movements performed by a robot, strip application, vision inspection, and bin assortment could happen at a much faster rate than our customer’s prior process.
The SDC team developed an automated assembly machine with the capability to accommodate two styles of jack modules. Robotic integration included a FANUC SCARA robot with two custom part grippers that could quickly and automatically change tooling as needed without manual intervention.
The machine vision system directs the robot to move the jack to the exact label coordinates on the foil label applicator feeding pad and precisely applies the shielding strip to the jack. The strip position and color are then measured and placement is verified. The part is moved to a reject or accept bin based on the results of the machine vision readings.
The integration of automatic tooling changeover for the two jack module types eliminated the need for manual intervention, significantly reducing machine downtime. This not only enhanced operational efficiency but also allowed operators to focus on higher-skill tasks, optimizing labor resources.
Robotic automation of a once tedious manufacturing process improved part quality and consistency, leading to a more streamlined production flow. The precise vision inspection ensured that each component met strict standards before moving to the next production phase, ultimately boosting overall production line efficiency.
With a machine rate of 30 parts per minute, the solution increased throughput while maintaining high-quality standards, positioning the company to scale production and meet growing demand without sacrificing performance.
At SDC, we specialize in building custom machines that optimize different stages of our customers’ production lines. By tailoring solutions to each customers’ specific needs, we help streamline their operations and improve efficiency. In this case, the automated assembly machine we developed for our customer successfully sped up the production of jack modules, eliminated downtime, and enhanced part quality. This is a perfect example of how we create machines that tackle unique challenges and increase overall productivity.
This project highlights our ability to design and implement robotic automation that transforms processes into fast, reliable steps. We often build multiple machines for our customers to improve different parts of their production lines, ensuring that every step is optimized. By combining advanced technology like vision inspection and automated tooling changeover, we continue to help businesses meet growing demands while maintaining high standards of quality and efficiency.
A: Automatic tooling changeover eliminates the need for manual intervention when switching between different types of jack modules, significantly reducing machine downtime. This feature improves operational efficiency by allowing the robotic system to quickly adapt to different parts without halting production, making the entire process faster and more reliable.
A: Robotic integration boosts production line efficiency by automating repetitive tasks, such as foil label application, vision inspection, and part sorting. The use of high-speed robotic motion and precise movements ensures faster production cycles, while the machine vision system verifies part quality. This results in reduced bottlenecks, consistent part quality, and a substantial increase in throughput, supporting the growing demand for electrical connectors.
A: Robotic assembly automation improves the efficiency and precision of manufacturing processes, such as the application of foil shielding strips to electrical connectors. By utilizing advanced technologies like robotic integration, automatic tooling changeover, and machine vision systems, this approach minimizes downtime, reduces human error, and increases production speed, ensuring consistent, high-quality results.
A: The foil label applicator, integrated with a vision inspection system, guarantees the accurate application of shielding strips to jack modules by verifying the strip’s position and color. This process ensures that the shielding is applied precisely, meeting the strict quality standards required for electrical connectors, and reduces errors that could affect the product’s performance in high-electrical environments.
