Industry: Electronic Item Assembly
Material Handled: Electronic Items, White Goods, Assembly, and Testing
Product Category: Roller Conveyor
Activity to be Mechanized/Automated:
- Assemble child parts and instrumentation while allowing rotation of the main assembly in motion.
- Perform power testing on the product during motion to ensure proper operation.
- Complete packing and transfer to warehousing, all integrated online.
A compact, efficient solution for assembling, testing, and packing TVs on a continuous rotating conveyor system. Designed to handle high throughput of 5 TVs per minute, the system ensures seamless operations with minimal downtime and maximum productivity.
Challenges vs Solutions
| Challenges | Solutions |
|---|---|
|
Moving Main Assembly with Rotating Parts: The main assembly had to rotate freely during movement for easy assembly. |
Idler Roller Carousel with Universal Chain Track: Central track with a universal bi-planar chain and idler rollers supported moving pallets with free rotation. |
|
High Throughput in Limited Space: Required 5 TVs per minute and multiple stations in a compact layout. |
Curved Path Assembly Stations: Multiple stations along the carousel path with racks, tables, and tools optimized for space. |
|
Continuous Power Supply for Testing: Required stable 230VAC 50Hz power during motion. |
Shrouded Bus Bar Cabling: Ensured continuous power to pallets with sockets for device testing. |
|
Efficient Packing and Takeaway: Packing needed minimal space and manual effort. |
Pick-and-Place Vacuum Lifter: Vacuum pump with suction grippers enabled easy packing and takeaway. |
Results / Benefits:
-
Cost Effective: Achieved ROI within 1 year, offering the lowest cost of ownership.
-
ncreased Efficiency: Carousel system enhanced operator productivity and output reliability.
-
Energy Saving: Equipped with IE3+ energy-efficient motors and optimized systems.
-
Low Capital Investment: Utilized proven, low-cost technology and components.
-
24x7x365 Running Capacity: Maintenance-friendly design ensured minimal downtime.
-
High Productivity: Reliable components and layout maximized operational throughput.