01
Problem
The need for a retrofit arose because production of the products previously manufactured on the existing machine had ended, and the assembly sequence, process steps, and quality inspection requirements of the new products were incompatible with the existing machine configuration. Accordingly, the aim was to reconfigure the machine for the new products and continue using the existing equipment in production.
02
Solution
The machine’s 10-station configuration was reorganized according to the assembly and inspection requirements of the new products. Servo-controlled O-ring, ring, and metal clip assembly, leak testing, lubrication, camera inspections, laser marking, and automatic sorting steps were adapted to the process flow of the new products.
03
System architecture
Mechanical Manufacturing → Mechanical Assembly → Electrical Manufacturing → Electrical Assembly → PLC Programming → HMI Design → OPC Communication
04
Technologies
05
Result
As a result of the retrofit, the existing machine was adapted to manufacture the new products and brought back into production. Assembly and quality inspection steps were aligned with the new product requirements, enabling continued use of the existing machine investment and extending its service life.
The following process sequence, beginning with manual pre-assembly and ending with automatic quality assessment, was addressed within the project:
Manual pre-assembly: Pre-assembly of the connector, O-ring, and ring components by the operator.
Station 1 — Product loading: Placement of the pre-assembled connector and metal clip into the station.
Station 2 — Empty station: A station where no operation is performed in the current operating configuration.
Station 3 — Servo-controlled O-ring and ring assembly: Completion of component assembly using a linear servo axis under the specified position and force conditions.
Station 4 — Leak testing: Inspection of the product for leakage using an ATEQ device.
Station 5 — O-ring lubrication: Application of lubricant to the O-ring.
Station 6 — Camera inspection of assembly and lubrication: Evaluation of correct ring installation and proper lubrication.
Station 7 — Metal clip assembly: Pressing the metal clip into the connector at the specified force and position using a linear servo axis.
Station 8 — Camera inspection of wire position: Inspection of wire position after assembly.
Station 9 — Result evaluation and laser marking: Combining station results; applying an OK mark with date and time information to conforming products, and marking non-conforming products with the NOK result and the reason for failure.
Station 10 — Marking verification and automatic sorting: Checking the accuracy of the laser-marked information and placing the product into the corresponding OK or NOK bin using a linear servo axis and gripper.
This configuration has enabled each product to be linked to its assembly and inspection results, the source of non-conformities to be identified, and products to be automatically sorted according to their quality status.