TECHNOLOGIES INCCASE STUDY

COMPONENTS SUB-ASSEMBLY LINE Automation Solution for the Automotive Industry

A customer in the automotive industry needed a second assembly line to handle increased production volume.

TCA's challenge was to use as much engineering as possible from the existing TCA-designed line so the two could e�ciently run in tandem. Working from the customer's part speci�cations, we created 3D designs for all the components and arranged the second line in a Z-con�guration to facilitate loading and changeover. In addition, we designed a second �ux supply line with a separate set of tooling to enable both lines to operate independently.

Occupying a 20 ft x 30 ft footprint, this assembly line has three main subsystems - a feeder, �ux applicator, and a stacker. Handling 6 parts per magazine, 6-axis robots are used to feed the parts to a servo index conveyor for pick and place transfer - a careful process monitored by machine vision cameras.

Next, a dual-head spray system electrostatically applies the �ux while a reclaiming system removes the excess. After air drying, the parts are fed to the assembly system, 2 per magazine in a nested position.

This assembly line underwent full functional testing as well as a 4 hour dry-cycle test before it was shipped to the customer in Mexico. In addition to supervising the site installation, our engineers supplied full documentation as well as operator training that encompassed maintenance, changeover procedures, and recommended fault recovery.

TCA Technologies Inc. | 38 Winer Road, Guelph, Ontario, Canada N1H 6H9 | Tel: +1.519.824.8711 | sales@tcatech.com

HIGHLIGHTS

This assembly line is the second assembly line of its type and was made to use as much engineering from the existing line as possible.

Powder-Coated, Welded Structural Steel Support FramesBlanchard Ground and Plated Table Tops

Tabletop Perimeter GuardingConstructed from Lexan in Extruded Aluminum FramesSafety-Interlocked Access Doors

Part Load Station180° Rotary Reciprocating Table4 Pallets for Braze FixturesStart Button

LEAK TEST STATIONSCARA Robot

650mm Reach Transfers Parts using Vacuum End E�ectorIntertech Dual Channel Instrument CalMaster for Leak TestCalibrated Ori�ce for Flow Test

Ink Jet Marker for Leak test Pass MarkingLeak test Reject part Stacking Fixture

High Level SensorTCA-Designed and Manufactured Hot Laminating SystemHIPOT TEST STATIOHipot Test Reject Part Stacking Fixture

High Level SensorSCARA Robot650mm Reach Transfers Parts Using Vacuum End E�ectorFlatbelt Discharge ConveyorAllen Bradley CompactLogix PLCAllen Bradley Panelview Plus 1000 Operator InterfaceAllen Bradley SmartGuard 600 Safety Controller

SYSTEM CAPABILITIES

10 ft x 30 ft

OVERALL SYSTEM DIMENSIONS

18 weeks

OVERALL LEAD TIME

Accepts Manually Loaded Braze Fixtures Containing Numerous Parts That Will Then be:

Leak TestedFlow TestedMarked w/ Ink Jet SystemRejected If They FailHot Laminated Both Sides W/ PET FilmHipot TestedMarked W/ Black Ink DotRejected If They FailIndexed to an Unload Station for Operator RemovalCycle Time of 9 Seconds

SYSTEM CAPABILITIES

DesignFully designed by TCA3-D design in SolidWorks

Manufactured in-house using our CAD/CAM equipment and capabilities.PLC ProgrammingHMI Design & ProgrammingSupervision of Site InstallationSystem CommissioningOperator TrainingDocumentation

Hard-Copy & CD-ROM Copies of ManualsAutoCAD Assembly Drawings & Schematics Warranty2 Years up to 6,000 Hours Running Time

CAPABILITIES APPLIED / PROCESSES

PROJECT DESCRIPTION

ABOUT TCA TECHNOLOGIESTCA Technologies is a leader in the design and manufacturing of custom industrial automation equipment. Building on 20 years of industry experience, TCA employs the most innovative technological solutions to conceptualize, develop, and execute cutting-edge automated manufacturing systems. A team of experienced engineers have developed manufacturing solutions for a variety of �elds such as R&D prototyping, welding, assembly, leak testing, material handling, plastics and composites, vision and accuracy. Catering to some of the world’s most successful manufacturers, TCA strives for excellence by developing sophisticated new or improved systems for industries such as automotive, energy, health sciences, electronics, and consumer products.

TCA Technologies Inc. | 38 Winer Road, Guelph, Ontario, Canada N1H 6H9 | Tel: +1.519.824.8711| sales@tcatech.com

TECHNOLOGIES INC