Assembly Job #0339 2018-04-23T14:44:51+00:00

Project Description

Equipment Description:                   LED Head Lamp Assembly Phase 2

Warren Industrial Solutions is offering to design, build and integrate an oval shape assembly line for the LED Head Lamp. Truck-Lite has specified a 10-station assembly and inspection layout for the line. Station #1 will have an operator loading die cast housings into the pallet fixture and unloading completed LED Head Lamp assemblies. Station #2 and #3 will have operators using manual presses to apply stick back adhesive to the reflector and transferring the reflector to the die cast housing with robotics possibly performing these steps in the future. Station #4 will have a fully automated press to apply proper pressure to adhere the reflectors to the die cast housing. Station #5 and #6 will have operators performing Aspheric assembly on the die cast housing at the pallet. Station #7 and #8 will have a Cognex Checker vision sensor for inspecting the high and low beams of the LED Head Lamp. Station #9 will be a reject station for removing pallets from the line that failed the vision inspection. Station #10 will have a Cartesian XYZ Positioning System or robot to dispense epoxy at precise locations. The following descriptions include what Warren Industrial Solutions and Truck-Lite will be responsible for per station.

FlexLink XT Pallet Loop:

Warren Industrial Solutions is offering a FlexLink double track XT system with 240mm x 240mm pallets. The system will have an oval shape and be 18 foot long x 4 foot wide and have a constant speed of 39 feet per minute. There will be (3) pallet stops, (6) lift and locate stations, (10) pallets without tooling, (10) 12mm proximity sensor mounting brackets, (2) 48” overhead light and (1) 12” x 48” angled shelf. The pre-integration controls for the Flex-Link system will consist of the following stations and operations: Station #1, #3 and #6 will include a product stop and an operator pushbutton box. Station #2 and #5 will include a product stop, a lift and locate station and an operator pushbutton box. Station #4, #7, #8 and #10 will include a product stop, a lift and locate station and 3rd party handshakes. Station #9 will include a product stop and a lift and transfer station. The electrical parts for the system will be base on Allen Bradley components and use a Micrologix 1100 PLC and PanelView 400 B&W HMI. There will be enough I/O for the quoted integrated stations along with additional space in the electrical enclosure for future expansion. All shipping costs to and from Warren Industrial Solutions along with set-up and debug at Truck-Lite is included in the price below.

 Pallet Tooling:

Warren Industrial Solutions will design and build the pallet tooling to locate the die cast housing accurately and provide connection points for the electrical plugs on the LED Head Lamp. There will be additional electrical connection points for allowing Station #7 & #8 to test the LED Head Lamp. The pallet tooling will be constructed from a combination of steel, aluminum, plastics and standard parts from quality manufacturers. The tooling will bolt to the pallet and will not be of a quick change design.

 Station #1:

There is currently nothing to integrate at this station.

 Station #2 & #3:

Warren Industrial Solutions is offering to motorize and automate the sticky back paper take-up of the Station #2 & #3 presses. The electronics and PLC programming will be integrated into the FlexLink controls.

 Station #4:

Warren Industrial Solutions will integrate the Press #2 that we are currently building into the FlexLink unit. There will be mechanical design, machining and assembly involved to modify and mount the press to the FlexLink unit. There will also be electrical wiring, PLC programming and touchscreen programming done to control the press.

 Station #5 & #6:

There is currently nothing to integrate at this station.

Station #7 & #8:

Warren Industrial Solutions will integrate (2) Cognex Checker vision sensors into the assembly line to check for proper high and low beam settings of the LED Head Lamp. Truck-Lite will supply all vision sensor equipment. Integration will include mechanical mounting of the vision sensors and display along with automation to power the lamp. The vision sensor and PLC set-up and programming are also included.

 Station #9:

There is currently nothing to integrate at this station besides minor PLC programming associated with Station #7 & #8 pass or fail conditions.

 Station #10:

Truck-Lite will be responsible for supplying and integrating the Cartesian XYZ system or robot for the epoxy dispensing at this station.

Assembly Job #0339-0153

Project Details

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