Assembly and Testing System 48V Drive

For efficient assembly and testing of customer-specific electrical drives with inverter assemblies, Sonplas has developed a semi-automatic, compact assembly line consisting of seven machines and one server as an additional facility. A sophisticated on-load and off-load concept ensures a fast process while doing so. The complete final assembly and testing of the components has a cycle time of only 37 seconds. A robot loads and unloads electric motors with the help of a pallet system. The same is also fitted with rolling gates in order to facilitate subsequent integration with the help of a driverless transportation system (AGV). The inverter is loaded manually and joined with the electric motor. Next, the machine carries out the required screw-driving and test processes (among others, a leakage test), labelling (applying type and warning labels) and flash-programming the components with the required software completely automatically. The robot handles the joining of the cooler connections. In contrast, the worker places the cooler connection caps manually. For the sake of quality assurance, a static and dynamic EOL (End-of-Line) test takes place finally as well as a final AOI (Automatic optical inspection). Consistent traceability is ensured with the help of the SonDaSys database, the customer MES system and product identification by means of DMC or barcode. Subsequent scaling is possible whenever desired thanks to the flexible line concept based on standardised assembly and test modules.