Electric Car Batteries Cell Assembly Line
Electric Car Battery Cell Assembly Line
The assembly line of Cell for Electric Car Batteries is a turnkey Project integrated in automatic cycle with one injection moulding press to produce the complete co-moulded modular cell then composing the electric car battery.
Starting from the aluminium coils and the raw plastic feeding to the press, it automatically performs the operations of aluminium cells forming and blanking, transfer to the assembly lines, handling, orientation and insertion into the injection mould, unloading of the cells, quality controls, orientation, loading of trays and stacking of the trays to form the final pallet, ready to be shipped to the End user.
Cycle time: 35 sec/12 pcs (multi-cavity moulding cycle of 12 cells).
Production and control operations:
- Forming and blanking of aluminium cells starting from coils.
- Quality control of the aluminium cells with dedicated camera.
- Buffer station of aluminium cells, fed by the production line, to allow production continuity at coils change.
- Transfer, handling and orientation of the aluminium cells with electric units and shuttles.
- High-rigidity cartesian robot with two units to load 6 aluminium cells each into the mould and unload 6 finished cells each from the mould.
- Orientation and transfer to the quality control and dummy stations.
- Vision systems to control the correct injection, the cleanliness of the aluminium surfaces – plates and wings without plastic scraps – and the presence and depths of holes.
- Cartesian robot equipped with special dedicated multi-picking units to load the finished cells to the tray laying on a deposit station, transfer the full tray to the pallet being formed and load the empty tray to the deposit station.
- Automatic conveyor chain to move the empty and full pallets.
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Assembly Line Gas Springs
Gas Springs Assembly Line 
The line automatically performs assembly and palletizing operations of gas springs, connecting in an integrated workflow a range of Products with different components configuration features and variable dimensions in terms of diameter and length.
The change of batch between different models is managed with no need of any set up; the components’ identification and control at entering the line lead to of the automatic calibration of tools and working stations along the line.
The application uses several different automation and control technologies, specifically integrated and customized to the functional and production time targets.
Steel bushings, stems and cylindric bodies of the Product are fed through dedicated dynamic warehouses, controlled and assembled with the relevant components before entering the main line.
The main line is made of different working stations, fed by a Cartesian axes transfer system up to the final palletizing of the Products into dedicated boxes.
Assembly and control operations:
- Dynamic warehouses for bushing, stem and cylinder body feeding, with consistency control of all components entering the line;
- Automatic feeding, robot screwing and control of valves and plugs on the main body;
- Automatic laser marking and Datamatrix reading for system supervision and traceability;
- Cartesian axes main line to transfer the components along the different working stations for assembly, control and palletizing;
- Automatic grease dosing with controlled axes for the different components;
- Automatic and controlled press fitting with automatic tools change;
- Automatic gas filling unit with control;
- Automatic feeding, control, orientation and insertion of plastic markers of different diameter;
- Automatic palletizing and pallets transfer at the end of the line.
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Automotive Shifter Assembly Line
Automotive Shifter Assembly Line
The workstations provide guided management of the picking of pieces from the slave warehouses through pick to light systems, a controlled process flow, the manual positioning in poka-yoke dedicated fixture of the components (all controlled by sensors) the start of the automatic assembly and control cycles in full safety.
Working orders are transferred from the IT central system connected to the line with bidirectional communication through a supervisor PC.
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Insert-Moulded Functional Subgroups Assembly Island
Insert-Moulded Functional Subgroups Assembly Island
The Functional Insert-Moulded Subgroups Assembly Island is integrated in an automatic cycle with an injection moulding press, equipped with its own handling system for press loading/unloading. It automatically performs operations of handling, assembling, control, laser marking and final unloading of functional insert-moulded subgroups.
An anthropomorphic robot feeds the dedicated deposits with steel components to be inserted by the press handling system in the mould at a set high temperature.
At the end of the pressing process the line receives from the press handling system, into dedicated seats, the insert-moulded Products.
The robot, equipped with specially designed multiple picking hand, transfers the Products to a rotary table; in the table working stations the quality of the moulding is controlled (plastic wings presence), plastic safety rings and metal screws are automatically fed and inserted into the Products, the parts are laser marked, identified with Datamatrix reading and finally unloaded into a motorized belt.
NOK parts are unloaded separately in proper boxes.
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Automotive Subgroups Assembly Island
Automotive Subgroups Assembly Island
The island automatically performs assembly, control, marking and unloading into dedicated boxes of automotive gears units functional subgroups, managing and controlling the different combinations of the components in accordance with the production batch.
The application uses several different automation and control technologies, specifically integrated and customized to the functional and production time targets; overall dimensions are fitting a limited available space.
The production batch of every component is identified by a barcode reader.
Components are automatically fed, the distinctive dimensions (inner and outer diameters, length, colour) are controlled, OK parts are loaded into high precision dedicated seats positioned on a rotary ring.
The use of a rotary ring table grants high precision and speed performances and an optimal efficient distribution of the working stations.
The ring working stations perform the insertion of a metal bushing, the press fitting of a plastic insert into the bushing, the insertion of a plastic sleeve and the edging of the bushing to complete the assembly, the rotation test of the sleeve, the marking of OK parts and their final unloading into boxes.
NOK parts are separately unloaded in every working station. Watch Video.
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Electric Meters Assembly Line
Electric Meters Assembly Line
The Electric Meters Assembly Line automatically performs assembling, labelling and control operations on plastic electric meters, connecting, in an integrated workflow, the welding operations before the line and the packaging lines at the end of the Process.
The application uses several different automation and control technologies, specifically integrated and customized to the functional and production time targets; overall dimensions to fit a limited available space.
The main body of the electric counter is identified by a barcode reader and positioned in a high precision dedicated seat on the motorized conveyor belt system.
It then proceeds through the different operating stations, where a plastic insert is fixed to the body, the cover is inserted, screwed and controlled, the label is wed out, applied and controlled, the dessicant salts bag positioned on the body and controlled.
All pieces are identified at the exit by a barcode reader, the OK proceed to the packaging, the NOK are separated.
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Household Components Assembly & Handling Bench
Household Components Assembly & Handling Bench
The Household Components Assembly and Handling Bench combines assembly and testing solutions in a unique automatic isle reserved for a sub-group of households.
The operations performed on the bench are the following:
- Manual loading/unloading of the product
- Control of flatness of the closing surface of the product with the help of a laser sensor.
- Loading the product : the antropomorphic robot transfer the OK piece to the proper seat.
- Magnet insertion.
- Magnet verification: a sensor verifies the exact orientation of the magnet (polarity) and its attraction force.
- Coating magnet with resin.
- Verification of resin coating : the 2D vision system verifies the correct uniform coating of the magnet and that no resin is out of the seat of the magnet.
- Unloading the product.
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Gearboxes and Gearmotors Handling & Testing System
Gearboxes and Gearmotors Handling & Testing Systems
Reference Line configuration:
- Handling system for inserting the product in the line.
- Pallet transport system motorized and with automatic return.
- Press fitting machines for different components, with operator panel, specific programs from centralized system, control of the diagram force/position and management of OK/NOK operations.
- Product’s tilting stations with PLC controlled axes, adjustable for different models, integrated to the press fitting machines or independent.
- Assembling and control stations, manual or automatic, with operator panel, specific programs from centralized system, operator’s feedback to allow transfer to following working stations, management of traceability of the assembled components and visualization of all provisions for the specific product.
- Test bench automatic functional at the end of the line: electrical tests and short circuit, efficiency, noise, vibrations, gasket sealing, static brake hydraulic tightness, static brake mechanical tightness, temperature, oil contamination.
- Management and Control software of the whole assembling and testing line, working programs setting and distribution to the different working stations, data collection data and back-up to relational database.
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Assembly and Testing Line
Assembly and Testing Line
Sytec Group Assembly and Testing Lines include all phases of mounting/assembling, quality control and full management of the production process. According to customer’s specifications, they may feature:
- transport systems and assembly/testing stations, manual, motorised or fully automatic;
- specific working stations for assembling and testing of functional subcomponents, synchronous with the main line;
- functional and electric testing stations of the finished product;
- visual evaluation and packing of the product, with communication to the warehouse management;
- shelves, carts and handling equipments according to Lean manufacturing.
Assembly and testing lines often include functions of control and traceability of all components. Process flow control implies processing information originating from each specialised station in the system: this guarantees that only products that have correctly completed the process, that is, the specific assembly and testing stages for each product type, are sent to the warehouse.
The focus of architectural development of the Sytec solution is the system flexibility, dozens of different finished product models even with reduced production batches may be processed. The solution uses modular components both for hardware and software management. Each work station can carry out different work stages depending on the product: even the assembly provisions may be managed to facilitate the information to be shown to the operators, dynamically, on each station, based on the model in transit.