Project Scope:
Microscopic Medical Device Assembly Machine
As an industrial automated machine builder, we were faced with a unique challenge – how to automate a previously manual and tedious medical device assembly at a microscopic level.
Due to the nature of the very small parts, it was difficult and time-consuming for our customer to assemble this component by hand. We had an opportunity to automate the process to reduce the cycle time and improve the yield.
Mecademic Meca500 6-axis industrial robot
Asyril Asycube50
SDC servo-driven transfer arms
Bellco Feeders vibratory bowl feeders
IPG vision-guided laser
Keyence XG-X vision system
Allen Bradley Compact Logix PLC & PanelView 5000 HMI
The machine concept:
This complex sub-assembly process needed to join a total of 26 links and 52 rivets per assembly. The automation process needed to have excellent capabilities in:
- Parts feeding
- Robotic material handling
- Laser welding
- Part stamping
- Microscopic assembly
- Vision inspection
- Conveying system
The accuracy of the machine came down to micron precision. The machine needed to have repeatability with equipment capable of handling such small parts. SDC sourced and tested equipment in phases to ensure each automated process on the machine would be performed with the most accuracy prior to the final build.
Our Solution:
The best route to ensure machine success was to break down several of the crucial assembly steps into phases. After the phases proved successful and the concept was finalized, SDC built a unique microscopic assembly machine based on the seven essential capabilities.
- Parts feeding
- Four different-sized links were supplied through their own small vibratory feeder bowls.
- An Asyril feeding tray allows us to pick microscopic rivets from bulk.
- Robotic material handling
- The four sizes of links are picked from the inline track on the feeder bowl by a servo-driven robotic gripper.
- The Mecademic 500 robot picks the link from a stamping station and places it on a mandril assembly station.
- The shank of the rivet is 12,000th of an inch in diameter. Due to their size, a servo-driven vacuum gripper suctions the rivet and transfers to a vision station.
- Part stamping
- Each link gets precise holes stamped for rivet insertion.
- Laser welding
- Microscopic assembly
- Link stamping station.
- Mandril placement for rivet insertion.
- EPG laser welder with a local guard enclosure.
- Vision inspection
- Part detection by a highly specialized camera lens and intelligent vision software for picking and positioning parts.
- Visual inspection for correct orientation for part alignment.
- Vision confirmation of accurate part assembly and product quality.
- Conveying system
- Pallets are supplied for the loading of completed medical devices with a conveying system.
Once the assembly is complete, the robot unloads the part onto a pallet with a 5-unit capacity.
Summary:
Through project stages, our machine concept reached each milestone with impressive results. This allowed our team to improve machine expectations to deliver a medical device of the highest quality at a remarkably consistent and repeatable rate. This project produced a robust, fully automated microscopic assembly machine that has resulted in the order of future machines just like it.
Our Medical Capabilities:
SDC and the medical manufacturing field.
Medical device manufacturing automation is advancing, promising enhanced productivity, quality, and consistency throughout the entire lifecycle—from development through product assembly and final packaging. The challenges faced by medical technology manufacturers lie in swiftly launching products while maintaining stringent safety, quality, and traceability standards. Each day gained in accelerating time-to-market translates into substantial economic value. This presents numerous opportunities to streamline efficiencies across all phases—from development and production to packaging and logistics.
Our team collaborates closely with our customers to craft solutions that meet meticulous requirements. From initial process development and specification to ongoing lifecycle management, we leverage our extensive experience to guide and support you. Our collaborative approach has empowered countless customers to evolve from concept and pilot lines to full-scale commercial production and beyond.
SDC specializes in designing custom machines to automate production and enhance factory efficiency beyond conventional manufacturing methods. Over the years, our team has meticulously engineered and constructed numerous machines for a diverse range of products. Each project is approached uniquely, integrating proprietary processes and equipment to meet all machine specifications.
Innovation Awaits: