Material Handling

Clip Assembly Automation for Riveting & Sealant Application

The client has expertise in the snow guard and roofing industry and is known for providing clips for standing seam roofing. They manufacture commercial standing seam roofing panels, PBR panels (Purlin Bearing Rib), C purlins, Z purlins, red oxide C channels, and galvanized channels. Their products are also sold in several countries across Europe, Asia and North America.

Scope

The client sought us to design a fully automated assembly line to streamline both the riveting and sealant application processes in the clip assembly. The design had to seamlessly integrate with their existing setup to ensure smooth workflow and maximum efficiency. The final design included:

  • Inline slat conveyor: to transport the components between different stations for riveting and sealant application.
  • Pick and place assembly: to pick the components from the slat conveyor and precisely drop them into the carton boxes on the exit roller conveyor.
  • Roller conveyor: to carry the finished components in the cartons to the next phase of the process.

Challenge

The key challenges in designing automation line for riveting and sealant application in clip assembly included:

  • Automated system: Designing the system to automate both the riveting process and sealant application according to the client's specific requirements was a challenge. The assembly line needed to produce 100 finished components per hour to align with their production demands.
  • Custom design for efficient component handling: The inline slat conveyor, including its fixtures and pallets, had to accommodate three variants of components without requiring any setup changes. Precise component handling was essential to prevent damage or misalignment during transport. Also the conveyor width had to be optimized for proper alignment with the riveting head.
  • Pick & place assembly: The components needed to be accurately transferred into carton boxes of two different sizes, as per the client’s requirements. Precise placement was crucial to avoid misalignment and ensure a smooth process.
  • Roller conveyor: The roller conveyor designed to carry carton boxes needed to accommodate different variants for different number of components.
  • HMI: The Human Machine Interface system should be able to accommodate different operator inputs and adjust speeds dynamically based on production requirements.
Clip assembly automation - rendered image

Solution

To address the challenges of designing an efficient automation line for clip assembly, we conducted in-depth research into design aspects to meet the client’s requirements and ensure smooth integration into their production process.

Our solution optimized the design of the inline slat conveyor, roller conveyor, and pick-and-place assembly. Here's a detailed breakdown of each part:

Inline Slat Conveyor Design

  • After several technical discussions between the designers and automation engineers, we leveraged our SolidWorks expertise to design an efficient inline slat conveyor. The conveyor included seven stations: four for manual operators, the fifth for riveting, the sixth for sealant application, and the last for unloading components.
  • We designed pallets and fixtures to accommodate different component variants without the need for setup changes. Poka-yoke technique was used to ensure error-proof handling.
  • We integrated a servo system to drive the slat conveyor, utilizing chains and sprockets, supported by bearings, tensioning, and guides. The pallets were fastened to the chains with A-type links to ensure secure transportation of components.
  • At the riveting station, we used a pneumatic clamp to securely hold the pallet and fixture while riveting, with extra support underneath the pallet to keep everything steady during operation. We also added sensors at both the riveting and sealant stations to ensure the components are always in the right position.

Pick and Place Assembly Design

  • We designed a pick-and-place unit to transfer the finished component from the inline slat conveyor to the carton box on the roller conveyor. The unit included a servo-driven linear actuator, vertical and horizontal pneumatic actuators and suction cups.
  • The vertical actuator with suction cups would pick the component from the fixture on the slat conveyor and the horizontal actuator would transfer it to the roller conveyor, placing it into carton boxes at different positions. To ensure everything aligned correctly, we used vision sensors for accurate placement.

Roller Conveyor Design

  • The roller conveyor was designed to carry empty and components-filled carton boxes to the next stage of the process. It is driven by rollers with built-in sprockets, connected to a geared motor with a variable frequency drive to control the speed.
  • We integrated pneumatic stoppers, a singling system, a pusher, and sensors to the roller conveyor. The pusher and stopper ensured proper placement of components, while the singling system prevented empty boxes from colliding. Sensors, placed at key points, monitored the movement of carton boxes. They would activate end stoppers to prevent the boxes from falling off the conveyor.
  • The design ensured that the roller conveyor supported seamless integration with other automation systems and machinery, improving the overall productivity.
  • We also ensured that all safety and ergonomic standards were met according to the client’s requirements.

The designs were developed with a focus on reliability and efficiency, taking into account the findings from the Design Failure Modes and Effects Analysis (DFMEA) to address potential risks and enhance system performance.

With the help of Sedin’s cost-effective and state-of-the-art industrial automation solutions, the entire cell was able to work continuously without any hassles, thereby increasing the productivity.

clip-assembly-automation-model-image.png

Value and Benefits

With wide experience in SPM (Special Purpose Machine) and material handling, Sedin could design the assembly line making it compact and simple in nature. Our commitment to quality and timely delivery has significantly helped the client reduce costs and increase productivity.

The final design could handle a wide range of products, offering solutions for various applications and allowing the client to adapt to future needs easily.

The automated system operated at high speeds, boosting component transport efficiency and increasing production rates.

The precise pick-and-place assembly and singling arrangement on the roller conveyor ensured accurate clip placement, preventing misalignment and production delays.

By automating the process, we helped the client reduce manual labor and cut costs, allowing the staff to focus on more value-added tasks. The system seamlessly integrated with their existing production lines, minimizing installation time and disruption.

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