DAS were commissioned by a major UK fire detector manufacturer to design & build a fully automated assembly machine for two of the components forming part of a Manual Call Point Product. Working with our partners at Mitsubishi Electric & Scorpion Vision, the solution consisted of two separate work stations within one machine linked by a 6-axis robot for loading & unloading. 5 vibratory bowl feeders feed the various components into the machine and a Camera system is incorporated on two of them to provide orientation data to the PLC/Robot as the products complexities didn’t allow conventional orientation methods to be used. The robot is then able to orientate, load & unload and reject as required. Pneumatically actuated Pick & Place technology is used to handle the more straightforward operations, while a Demag electric screwdriver inserts a screw to the correct torque. With a throughput of 300 of each component per hour this machine provides a highly efficient production cell.
Client: Leading Manufacturer of Fire Detection and Alarm Devices
Partners: Mitsubishi Electric, Scorpion Vision
To enhance throughput and quality control in the assembly process of two key components for a Manual Call Point product by designing and building a fully automated robotic workcell.
Design & Automation Solutions (DAS), in collaboration with Mitsubishi Electric and Scorpion Vision, delivered a fully automated assembly system consisting of two dedicated workstations linked by a Mitsubishi Electric RV-4 6-axis robot within one machine.
Significantly improving the efficiency and precision of the client’s component manufacturing, the system integrates two sub-assembly cells which inserts and tightens screws, as well as applying brass inserts into injection mouldings.
A Mitsubishi Electric RV-4 6-axis robot links both applications, managing all loading, unloading, pick-and-place operations, and ensuring smooth integration across the assembly line. With a target throughput of 300 parts per hour per function, the automated workcell outperforms manual assembly by increasing both speed and accuracy.
Key elements of the system include:
- Vibratory Bowl Feeders: Five feeders deliver components into the machine, with two of them incorporating Scorpion Vision camera systems to capture orientation data and overcome challenges where conventional orientation methods were not viable.
- Advanced Robotics: The Mitsubishi Electric RV-4 6-axis robot manages component orientation, placement, and rejection, ensuring seamless coordination between both stations.
- Precision Assembly: Pneumatically actuated pick-and-place units handle straightforward insertions, while a Demag electric screwdriver automatically inserts screws to the correct torque.
- Control and Interface: A Mitsubishi Electric Q Series PLC with GOT 2000 HMI provides intuitive operator interaction. Remote I/O (iQ-F PLCs) and a CC-Link IE field network ensure fast and reliable communication across all devices.
- Automation Cells: Two sub-assembly stations linked by a Mitsubishi RV-4 6-axis robot
- Component Orientation: Vision-guided orientation system using Scorpion Vision technology
- Advanced Control: Mitsubishi Electric Q Series PLC, GOT 2000 HMI, iQ-F remote I/O, and CC-Link IE network
- Automated Screw Driving: Demag electric screwdriver for torque-controlled insertions
- Flexible Handling: Pneumatic pick-and-place units for reliable component transfer and placement
- Integrated Rejection: Automated reject handling for out-of-tolerance or misaligned components
- Increased Throughput: Achieving 300 parts per hour per function, significantly outperforming manual assembly processes
- Enhanced Quality Control: Automated vision and orientation systems ensure consistent accuracy and reduce assembly errors
- Ease of Use: Operators report positive feedback thanks to the intuitive HMI and straightforward system integration
- High Reliability: Consistent, repeatable performance in demanding production environments
Richard Allen, OEM Business Development Manager at Mitsubishi Electric, said,
DAS has truly raised the bar in productivity and quality control with this project. The new system demonstrates the strength of our partnership and showcases what our ecosystem can achieve in real-world applications.
