Probe Assembly Line

The Challenge

The challenge was to design, develop and build a complete line to assemble the device. The device comprised 14 components, which in turn made up four sub-assemblies, ultimately making up the main device assembly. SP Automation and Robotics worked closely with the client to establish the best build process for the device.

• Produce a fully assembled device every 25 seconds.
• Ensure 100% inspection of the device throughout the process.
• Modular construction to aid assembly.
• Cater for various device configurations.

The Solution

The final assembly solution measured fourteen meters in length and comprised four modules, each carrying out assembly and testing of one of 4 sub-assemblies.

Module #1 assembled the main “wand”, requiring auto feeding of stainless steel tubes, carbide components and O rings. In addition, laser welding, feeding of control wires (small diameter), along with feeding and heat-shrinking protective sleeve before final assembly. Two Staubli TS 90 robots were used for assembly and then conveyed to module #2.

Module #2 dispensed and cured adhesive at two locations and bonded the sub-assembly from Module #1. Assemblies were delivered to a manual operating position before being loaded into Module #3

Module #3 assembled the handle to the “wand” using a Staubli TS 90 robot. Two halves of the device handle were automatically fed and loaded into fixtures. A flexible PCB was then inserted and wrapped around one-half of the handle. The robot removed the wand from a curing oven and inserted it into the handle assembly. The glue was dispensed and cured in one of two UV curing positions. The handle was assembled, clipped together, and placed onto a feed conveyor.

Module #4 ultrasonically welded, tested and then printed the device with an appropriate logo.