Fully Automated Assembly Machine and Control System

SDC designed and developed a machine and control system that successfully automated the assembly of a coupling used in the natural gas industry. The experts at SDC integrated two servo indexing chassis’ that were connected by a puck handling conveyor system and surrounded by multiple SDC Flex Feeders and Vibratory Bowl Feeders. One of the indexing chassis’ built the subassembly, while the other built the main assembly. A servo-driven press station on the main assembly chassis mated the two assemblies together to create the finished part.

First, a FANUC robot picks a stiffener from a feeder bowl and places it onto a chassis fixture. A Keyence probe is used to verify that the correct stiffener was picked. Then, a FANUC robot picks a hub seal off of an SDC Flex Feeder and places it on top of the stiffener. A pneumatic cylinder presses the hub seal down on the stiffener. A Keyence probe is used to confirm that the hub seal is the proper depth.

Next, a FANUC robot picks a retaining ring off of an SDC Flex Feeder and places it on top of the hub seal. Then, a FANUC robot picks a stiffener O-ring off of an SDC Vibratory Bowl Feeder and places it precisely in the stiffener O-ring groove. A Cognex machine vision system is used to verify that both the retaining ring and the stiffener O-ring are present.

A servo-driven greasing station is used to apply grease to the stiffener O-ring using three axes (X, Z, and rotational) of servo motion. A GP Reeves system is used as the grease dispensing platform. A Cognex machine vision system is used to verify that the grease was properly applied.

Meanwhile, as the main assembly is being built, a subassembly is built simultaneously. For the subassembly, a FANUC robot picks a body off of an SDC Vibratory Bowl Feeder and places it into a chassis fixture. A laser sensor is used to verify that the body was successfully transferred into the chassis.

Then, a FANUC robot picks a collet off of an SDC Flex Feeder and places it into the body; the placement of which is then verified by a Cognex machine vision system. A FANUC robot picks a thrust washer off of an SDC Vibratory Bowl Feeder and places it into the body on top off the collet. A Cognex machine vision is used to verify that the thrust washer was placed onto the collet.

At the servo-driven greasing station, where a GP Reeves system is used as the grease dispensing platform, grease is applied to the center of the body using three axes (X, Z, and rotational) of servo motion. A Cognex machine vision system is used to verify that the grease was properly applied.

A pneumatic cylinder is used to place a body O-ring into the body. From there, a feeder bowl is used to feed the body O-ring to the cylinder. A pneumatic cylinder with a sensor is used to verify that the body O-ring was properly placed.

Again, a servo-driven greasing station is used to apply grease to the top of the body. Then, a two-axis servo system transfers the completed subassembly into a puck. A two-axis servo system picks a completed subassembly out of a puck and transfers it onto the main assembly dial.

A servo-driven press is used to mate the subassembly onto the main assembly. A CO2 laser marks a date code on the finished part, which is verified by a Cognex camera. Once the assembly is complete, a FANUC robot picks the finished assembly off of the chassis and palletizes it in a box.