Automating Sensor Assembly

At Lumis Automation, we are committed to revolutionizing manufacturing processes with our automation solutions. Our latest collaboration is focused on automating the sensor assembly process for a prominent instrumentation company. This project exemplifies our expertise in designing, fabricating, and implementing advanced robotic systems tailored to specific client needs.

Project Overview

The aim of this project is to develop and install a turn-key robotic system to automate a critical step in the sensor assembly process. This comprehensive solution includes design, fabrication, programming, installation, and continuous research and development to ensure optimal performance and efficiency.

Key Features and Technologies

1. Robotic System Design:
Our team will design a customized six-axis industrial robot system. This system will feature a vision system for precise part identification and placement, a control panel for seamless operation, and a touchscreen interface for user-friendly control and monitoring.

2. Fabrication and High-Quality Components:
The robotic system will be fabricated using high-quality components, ensuring durability and reliability. The system will include a six-axis collaborative robot, vision systems, control hardware, and a touchscreen interface.

3. Precision Programming:
The robot will be programmed to handle parts from trays and load them into a pin station for assembly. The programming will ensure smooth and accurate operation, with capabilities for precise positioning and movement.

4. Installation and Integration:
Our team will oversee the installation of the robotic system, ensuring proper setup and integration with existing processes. This includes the setup of hardware, integration of the control panel and touchscreen, and ensuring all components function seamlessly.

5. Research and Development:
Continuous R&D efforts will be made to refine the system’s performance. This involves prototyping, testing, and iterating on the design to achieve the desired outcomes.

Screwing Technology

One of the standout features of this project is the advanced screwing technology used for sensor assembly. We utilized a two-axis servo motor system, which includes:

• Linear Axis: This component pushes the screw into place with precision, ensuring that each screw is accurately positioned.
• Rotary Axis: Once the screw is in place, the rotary axis drives the screw to the target torque, ensuring a secure and consistent assembly.

In addition to this mechanical precision, epoxy is applied to the parts before screwing. The robot picks up each screw, moves it to the dispense station where epoxy is applied, and then positions the screw in the assembly. The use of epoxy ensures that each component is securely fastened, adding an extra layer of durability and reliability to the assembled sensors.

Handling Tiny and Fragile Parts with Precision

The sensor assembly process involves dealing with extremely small components, including delicate crystals that are easy to break. To handle these tiny and fragile parts with care, we implemented a stepper-driven two-finger gripper with force control. This technology allows the gripper to adjust its grip force precisely, ensuring the parts are handled gently without causing any damage.

The advanced gripper technology, combined with precise robotic control, enabled the efficient and accurate assembly of these minute components, ensuring each part was perfectly aligned and secured.

Vision System for Quality Control

To ensure the highest quality and accuracy, the system includes a sophisticated vision system. This vision system measures and inspects the sensor assemblies for misalignment and other defects. By capturing detailed images of each part, the vision system can detect even the smallest discrepancies, ensuring that only perfectly aligned and assembled sensors move forward in the production process.

The vision system plays a crucial role in maintaining the high standards of quality required for sensor assemblies, providing real-time feedback and enabling immediate corrections if any issues are detected.

Benefits of Automation

Increased Efficiency:
The automated system will significantly enhance the speed and accuracy of the sensor assembly process, reducing manual intervention and potential errors.

Consistency and Reliability:
High-quality components and precision programming ensure consistent and reliable performance, leading to higher quality sensor assemblies.

Scalability:
The system is designed for expandability, allowing for future upgrades and integration with additional sensor models.

Operator Training and Support:
Comprehensive training and support ensure smooth transition and operation of the new system, with minimal downtime.

At Lumis Automation, we pride ourselves on delivering innovative automation solutions that drive efficiency and performance. This sensor assembly project is a testament to our commitment to excellence and our ability to meet the unique needs of our clients.

For more information about our automation solutions, please visit our website or contact us at info@lumisautomation.com