Automated Manifold Assembly
Project Overview
Lumis Automation, an industrial automation company based in Orange County, California, designed and built a fully automated robotic assembly system for a client’s manifold production line. The system utilizes two Mitsubishi industrial robots to perform precision assembly of valves and plugs onto aluminum manifolds. Each robot picks components from dedicated trays and automatically screws the parts in place using interchangeable tooling. This solution replaced a labor-intensive manual process with a reliable, high-speed automated system — improving consistency, throughput, and overall manufacturing efficiency.
Engineering & System Design
Our engineering team completed the full mechanical design of the automation cell using SolidWorks, developing custom tooling and tray-handling systems to handle multiple component types. The dual-robot system uses quick-change end-of-arm tooling to switch seamlessly between grippers and screwdrivers, allowing both robots to share assembly operations efficiently.
The control system design and software development were completed entirely in-house by Lumis Automation. Our engineers developed a PLC-based control platform integrated with both Mitsubishi robots, ensuring synchronized motion, torque monitoring, and quality validation. The system also features an intuitive HMI interface for operators to select product recipes, adjust parameters, and monitor system performance.
Results & Benefits
This automated manifold assembly system reduced cycle time, eliminated manual variability, and delivered consistent torque accuracy across all fasteners. The design also allows for rapid product changeover through programmable recipes, making it adaptable to future product variations.
Key benefits:
Improved product consistency and torque accuracy
Reduced labor costs and manual assembly time
Increased production throughput
Enhanced flexibility with multi-tool automation
Key Technologies & Capabilities
Dual Mitsubishi industrial robots for coordinated assembly
Custom SolidWorks mechanical design and fixturing
Quick-change robotic tooling (screwdrivers and grippers)
PLC and HMI integration with custom software
Torque feedback and quality monitoring
Lumis Automation provides robotics integration and industrial automation engineering services throughout Southern California, specializing in robotic assembly systems, vision inspection, and custom machine design. Our multidisciplinary team combines mechanical, electrical, and software expertise to deliver end-to-end automation solutions — from concept to commissioning.