Cyan Tec Commissions Fully Automated Assembly Line

Cyan Tec has recently commissioned a fully automated assembly line for one of its high-profile automotive customers.

Following on from previous successful contracts with said client, Cyan Tec were successful in securing the business for what turned out to be a significantly more automated and complex assembly system than its predecessors.

The Cyan Tec machine can assemble a range of different lengths of components, with an innovative “fixed side” and “moving side” approach included in the design to allow the machine to be automatically adjusted to suit the part being processed.

Starting from the raw material being presented to the line on a reel feeding system, a part is cropped to the required length and profile prior to it arriving at the dedicated assembly section of the machine.

The part is placed onto a servo driven walking beam mechanism, used to transfer the component through the various assembly stations.

Both ends of the component are formed into a “loop” to prepare it for the insertion of the fixings that are used to hold the final part in place when it is installed onto a vehicle. A combination of pneumatic and electrical devices are integrated at the “looping” station to accurately perform this forming process.

Automatic bowl feeders, linear tracks and end escapements are provided with the machine, and they are used to autonomously feed a variety of different fixings to a known end position. Once the fixing is sensed to be in position, the machine automatically inserts it into the previously formed “loop” at both ends of the component, and a hydraulic press is deployed to form the top of the part, securing the fixing in its final position.

A traditional spot-welding setup is installed at the next station, and this performs a pair of spot welds on the component, securing the previously inserted fasteners in place. Due to the welding and product requirements, significant machined tooling is required at this position in the machine. Cyan Tec has vast experience in the design and manufacture of bespoke and modular tooling systems. Not only in the automative industry, but the company has also provided dedicated fixturing to the aerospace and consumer product market.

Once the component has been fully processed by the automated assembly machine, a six-axis robot is used as an end of line pick and place mechanism. Provided by Cyan Tec’s strategic partner, ABB, the robot is designed with a bespoke gripper to suit the range of components that are required to be handled. A relatively small robot is installed here, though Cyan Tec has robot integration experience with the full range of ABB robots, including using many features within the high-performance controller. The machine uses the ABB “Safe Move” technology to ensure the ensure the areas around the machine are protected from collision, creating safety zones with the aim of eliminating commercial risk for the end user.

In addition to Cyan Tec’s envious reputation for producing high-quality industrial laser and digital inkjet printing systems, the company has the required engineering experience to design and deliver a complex, bespoke assembly solution. If you have a requirement for a new system, then please get in touch with our sales team – sales@cyan-tec.com – to start your automation journey with Cyan Tec.