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AUTOMATED
CELL PHONE PRODUCTION SYSTEM
LASER SPOT WELDING & MACHINE VISION INSPECTION
2 UP TOOLING – 2 SECOND CYCLE TIME PER UNIT
DESIGN LAYOUT, LASER WELDING SYSTEM –
Cell Phone Frame/Vibration Clip production rate
of 2 units every 4 seconds.
Six (6) Station rotary Index System (Two Up Tooling):
1 Load Frame, 2. Load vibration Clips,
3. Laser Spot Weld, 4. Machine Vision Inspect,
5. Reject Station, 6. Unload Welded Assembly.
Second Phase of project replaced operators with
one Pick n Place robot, from and into trays.
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Photo
– Automated Cell phone welding and machine
vision inspection system
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INTEGRATED
LASER WELDING SYSTEM FEATURES (Class 1 safe operation
system):
- The
Laser Station includes a pulsed nd:YAG laser with
two fiber optic cables each with a weld head delivering
25 joules of pulsed laser energy for the time
share sequential welding of the two Piston Assembly
weld joints; 1. Four (4) Spot Welds each 900 apart
(Disk OD to Piston ID), 2. Seam weld Pin around
bottom in bottom of Piston. Total Cycle time including
automated loading and unloading to and from the
welding fixture is < 30 seconds per Piston
Assembly.
- The
system design includes an automated system to
sequentially rotate the Piston Assembly for the
sequential welding of both weld joints. The two
fiber optic delivered laser beam weld heads are
mounted in a fixed postion on opposing sides (1800)
of the rotating Piston Assembly. The rotary indexer
is a servo driven rotary fixture with self-centering
clamps to vertically hold the Piston Assembly
in line with the laser beams. .A programmable
optical beam diverter sequentially couples the
laser beam into each fiber weld head positioned
for each weld joint.
- A
Class 1 laser safe enclosure shields the operator
from any laser radiation. The piston conveyor
is an asynchronous indexing unit with pallatized
fixtures that singulate each Piston Assembly,
and holds the Piston Assembly in a fixed upright
postion. The Laser Welding Station has an automated
pick and place unit to pick n place each pistion
into the rotary fixture. A parts presence sensor
trigers the laser weld cycle. After completion
of the weld cycle, the a pinc n place unit unloads
the Piston Assembly onto an output conveyor.
- A
PLC was programmed to interface with the Laser
for control of the complete systems cycle.
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AUTOMATED
LASER WELDING-MARKING, INSPECT (weld), & TEST
SYSTEM – Layout Diagram:
Eight (8) Station automated Synchronous Rotary Index
system. Stations: - #1 Auto Load, #2 Vacant, #3
Hi Pot, #4 Laser Weld & Inspect, #5 Hi Pot,
#6 Laser Mark, #7 Unload, #8 Vacant |
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AUTOMATED
LASER WEB CUTTING SYSTEM – CONFIGURATION LAYOUT
DIAGRAM |
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