Automotive Industry
Since the introduction of the assembly line, automotive manufacturers have looked for innovative ways to assemble parts, inspect and test parts, remove the human element from material handling, and better ways to dispense sealants. Our automation projects are flexible and range from semi-automated solutions to complete integration of robotics and vision tools into the manufacturing process. If you’re looking to save time, increase capacity, and reduce repetitive stress on your employees, Alliance Automation can help evolve your current processes.
Lamp Assembly, Test Machine, & Packout
The Project
This cell had to assemble (5) components into (1) Cargo Lamp Assembly every 10 seconds or less. Vibration welding took 30 seconds to complete, so in order to meet the goal of a 10 second machine cycle time, (4) Cargo Lamp Assemblies had to be welded at the same time. Each part was tested at 1.0 psig pressure decay with 12VDC. Light color and intensity met current limits of 164 mA +/- 15% mA. Production data was retrieved from the PLC through the HMI. This included recording date code or fail code being laser etched to the housing for traceability. Scrap and system failure rate had to be 1%, this meant removing the human element from the assembly process. A cabinet tray feed system was developed to allow the operator to load and unload the parts outside of the work area, allowing the robot to continue picking parts from another tray in the work area.
Auto Load Trimmer and Assembly
The Project
This assembly cell used a combination of robots and automation to move a seal through 9 stations that test, visually inspect, lubricate, dry and mark each part. The automation increased throughput removed repetitive tasks, reallocated operators, and improved quality. Grippers used in this process were embedded with weight sensors to ensure lubricant was applied properly thus reducing costs of over application. Seals were properly cured to exact specifications and each seal was marked allowing for traceability. The updated seal loading/unloading process allowed for a single operator to manage the entire process.
Assembly Line
The Project
The assembly line had to meet ergonomic designs, provide audible sounds and visual indicators for each step and be remotely accessible for future support by Alliance Automation. Quality assurance requirements were achieved by having an operator select a part number from a list, the part is scanned and verified at each station to confirm sonically welded and components are verified. This system checks for proper paint colors, wire harness testing, CHMSL testing, and lot codes allow for traceability recording.
Stand-Alone TPMS Snap-In
The Project
This stand-alone TPMS snap-in machine was built to remove repetitive processes by operators, maintain production rates, and to ensure the proper seating of the valve stem. The system had to be able to size the height and width of each wheel, elevate the wheel from the transfer conveyor, rotate the wheel, locate the valve hole, and position the wheel such that the valve hole is presented to the TPMS snap-in device. The snap-in device had to retract to allow an operator to place a TPMS valve-stem into the device’s part holder, the operator triggers the system and the device returns to the line and snaps the stem fully into the wheel.
Lamp Assembly, Test Machine, & Packout
The Project
This cell had to assemble (5) components into (1) Cargo Lamp Assembly every 10 seconds or less. Vibration welding took 30 seconds to complete, so in order to meet the goal of a 10 second machine cycle time, (4) Cargo Lamp Assemblies had to be welded at the same time. Each part was tested at 1.0 psig pressure decay with 12VDC. Light color and intensity met current limits of 164 mA +/- 15% mA. Production data was retrieved from the PLC through the HMI. This included recording date code or fail code being laser etched to the housing for traceability. Scrap and system failure rate had to be 1%, this meant removing the human element from the assembly process. A cabinet tray feed system was developed to allow the operator to load and unload the parts outside of the work area, allowing the robot to continue picking parts from another tray in the work area.
Auto Load Trimmer and Assembly
The Project
This assembly cell used a combination of robots and automation to move a seal through 9 stations that test, visually inspect, lubricate, dry and mark each part. The automation increased throughput removed repetitive tasks, reallocated operators, and improved quality. Grippers used in this process were embedded with weight sensors to ensure lubricant was applied properly thus reducing costs of over application. Seals were properly cured to exact specifications and each seal was marked allowing for traceability. The updated seal loading/unloading process allowed for a single operator to manage the entire process.
Assembly Line
The Project
The assembly line had to meet ergonomic designs, provide audible sounds and visual indicators for each step and be remotely accessible for future support by Alliance Automation. Quality assurance requirements were achieved by having an operator select a part number from a list, the part is scanned and verified at each station to confirm sonically welded and components are verified. This system checks for proper paint colors, wire harness testing, CHMSL testing, and lot codes allow for traceability recording.
Stand-Alone TPMS Snap-In
The Project
This stand-alone TPMS snap-in machine was built to remove repetitive processes by operators, maintain production rates, and to ensure the proper seating of the valve stem. The system had to be able to size the height and width of each wheel, elevate the wheel from the transfer conveyor, rotate the wheel, locate the valve hole, and position the wheel such that the valve hole is presented to the TPMS snap-in device. The snap-in device had to retract to allow an operator to place a TPMS valve-stem into the device’s part holder, the operator triggers the system and the device returns to the line and snaps the stem fully into the wheel.
Automotive Automation Opportunity Areas:
- High Speed Assembly
- Quality Inspection
- Palletizing
- Packaging/Shipping
- Testing
- Material Handling
- Glass Application
- Press Automation
- Powertrain
- Sealer, Paint, and Dispensing Applications
- Assembly Solutions; Part & Body Assembly
- Tire & Wheel Systems
- Fiber Processing
- Inspection & Testing
- Laser Application
- Material Handling solutions
- Metal processing
- Micro precision applications
- Plastics Processing
- Robotics Integration
- Software & Data
- Integration
- Vision Applications
Companies need a partner they can trust to install robotics, vision, laser inspection, sensors, and part testing into their production lines. Whether it is a fully automated line or specific tasks, automated equipment is ideal for completing repetitive tasks like moving parts across stations, applying sealants, and joining materials.
Is Automotive Automation Right for your Business?
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Is your current manufacturing process struggling to meet quality standards?
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Do you have a new product or change to a product that you need to add to your production process?
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Is it time for your company to bid for new business opportunities and gain assistance?
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Have you struggled with labor requirements for production?
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Are your current customers requesting new functions or testing to be integrated into production?
Why you should Join the Alliance
When you partner with Alliance Automation you're getting more than just a robotic solution.
Alliance Automation is here to design, build and install a custom solution to fit your exact needs. Our products will solve your business challenges. How? We follow the Alliance Proven Process. Alliance Automation doesn’t just sell you a product; we get to know your business and find solutions to help you reach your goals.
What we offer:
- Project Review
- Risk Analysis and Risk Assessments
- Budgetary and complete project proposals
- CAD Designers
- Fabrication
- Toolmakers
- Machinists
- Mechanical Engineers
- Electrical Engineers
- Controls Engineers
- Project Managers
- Full Implementation teams