Project Detail

Simplimatic created a custom material handling and automation assembly line for a major home appliance manufacturer to assemble a three-part dishwasher door assembly. The system featured dual-strand conveyor, custom pallets, a 192 kN air-to-oil hydraulic press, and a custom screwdriving cell. Simplimatic integrated and paired all of these components with custom controls and programming to successfully fulfill each customer requirement.

Our standard quality construction

For over 50 years the Simplimatic brand has been synonymous with quality and longevity throughout the manufacturing and packaging sectors. Simplimatic provides conveyor systems, robotics, and custom factory automation for a variety of manufacturing, assembly, and packaging operations worldwide. Simplimatic is committed to developing smart and simple solutions to help solve complex challenges. By utilizing a variety of tools and relationships, Simplimatic is able to fulfill customer’s requests with both off-the-shelf and custom material handling and automation projects. Simplimatic is also dedicated to the on-time delivery of quality products at a competitive price and is backed by the best customer support in the industry.

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After integration within the customer’s facility, the stamping cell is designed to:

  • Dramatically increased throughput
  • Decreased cycle time through the reduction of manual processes
  • Decreased worker error and fatigue
  • Features worker-friendly controls
  • Functions as a completely-customized manufacturing solution

Client : U.S. Based Consumer Appliance Manufacturer

Location : United States

Completed : July 2016

Description

For this manufacturing line, Simplimatic integrated twin-strand conveyor, a hydraulic press, and a screwdriver platen with three separate screwdrivers. The components were required by the customer and purchased from third-party suppliers. These components were then programmed to flawlessly work together to automate the customer’s manual assembly processes.

The line begins with the dishwasher product’s parts being placed together manually, then adhered using an interference fit through staking with a hydraulic press. After the product is fitted, it then travels on the assembly conveyor to a screw driving station which Simplimatic integrated within the line and fitted with custom controls and programming. The screw driving platen is fitted with pneumatic controls and sensors to control screw driving torque. Additional sensors are also used to ensure the screws are driven correctly.  Each custom control programmed by the Simplimatic engineers was chosen to ensure the system works reliably in the customer’s unique manufacturing facility.

The Challenges

The system was extremely rate sensitive, meaning production throughput needed to be quick and reliable to meet the deadlines for each production run. The door needed to be assembled in under 10 seconds, including successfully completing each phase of production such as manual assembly, staking, and screw driving. To accommodate the rapid rate of production, the Simplimatic team altered the screw driving platen to drive the five screws in sets, pneumatically controlling the screw drivers to change product sides quickly. The Simplimatic team engineered each step of production to ensure maximum efficiency for the customer.

Project Goals

Another goal for the system was to further improve the customer’s product integrity through the automation of the screw driving process. By automating this step, each screw is applied with the same amount of torque and checked with sensors to ensure they are driven in successfully each time. Therefore, each product is more securely built and the process is more repeatable through the use of automation.

The main goals for the stamping line were to program the screw driving platen with consistent torque to prevent damage to the product or inconsistent holds between components. Each step of the system needed to be completed in enough time to ensure the 10 second cycle time was maintained.