Assembly Line for Control Electronics

Sonplas has developed a fully automated machine for the assembly and testing of control electronics (control circuit boards and control devices). It can be used to assemble a total of two different types of control electronics. In order to save time, the components are fed to the machine in blister packages by means of a provided feeding device. Robots remove these packages fully automatically and process them further. The components can be identified using DMCs. A database stores all the results and process parameters, which it can subsequently allocate to the individual components. The machine fits the components “plug” and “shield” on a control board. These processes are monitored by cameras. Next, a 2K filler material is applied to the metal bottom housing. After that, the control board is fitted onto the metal bottom housing. A laser then labels the plastic top housing, which is placed on the control board by a robot later in the process. Using camera monitoring and infrared detection, a riveting press then inserts rivets along the swash circumference to attach the plastic housing.
This is followed by fully automated electrical tests (EOL test,) an air leak check and a position check. Finally, a laser labels the metal housing with a DMC and plain text. The robot places the finished components back onto the blister package, which the operator can take away in small load carriers. The assembly process of a control electronics component requires a cycle time of under 13 s. The machine runs autonomously for at least 20 minutes without any operator intervention. Portable control panels allow operators to easily control and monitor the process at every module. Defective assemblies can be efficiently sorted out into reject and rework trays, processed and, if necessary, fed back into the machine.