Case Study: Heavy Duty Brakes Assembly and Test Line
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Overview:
This semiautomatic system was developed to increase significantly the flexibility for production of product variants. Standardized ATW solutions were implemented to improve availability, MTBF, maintainability and accessibility.
Values & Benefits:
  • Non-synchronous system with highest process capability and reliability
  • Overall system availability > 97%
  • Turnkey assembly & test system with flexibility for part complexity
  • Statistical analysis of faults using process database
  • Upgradeable system for increased throughput
 
Solution:
  • The line consists of 19 assembly and inline test solutions.
  • Transfer through the line is accomplished by a heavy duty chain driven conveyor system.
  • 30 multifunctional heavy duty tronion pallets are used for maximum load of approx. 350 kg each.
  • PC controlled work order management.
  • 50 different brakes can be assembled using high flexible parametric system.
Highlights:
  • Multifunctional work piece carrier, pre-equipped for 4 brake sizes, change over by simple turning of the central shaft.
  • Flexibility for various sizes utilizing quick change adapters.
  • Highly robust heavy weight system for carrier weight up to 350 kg.
  • Wide range of product dimensions (up to 25”).
  • Flexible greasing systems for automatic change over.
  • Torque / angle controlled screw processes up to 500 Nm, variable automatic positioning.
  • Several of ATW standard 3-axis drive modules.
  • All parts feeding central from the rear (automatic side) to the front manual operation side.
  • System designed for easy upgrading in terms of automation and cycle time reduction.
  • System controls and design allows for lot size 1 with automatic change over.
  • Additional color coding on the brake surface to visualize passed processes.
  • Automatic part tracking through the line.
  • Documentation and storage of all process data for each single brake in a central database with ATW standard software.
  • High flexible precision measurement systems to ensure full functionality of the product.