Bracket Assembly Automation System
We designed and delivered a compact, efficient, and high-precision Bracket Assembly Machine for our client, automating the assembly of two bracket variants within limited floor space, with a 2-hour replenishment cycle, and aiming for zero human error and defects.
The Opportunity
The client required a compact, efficient, and high-precision machine to automate the assembly of two bracket variants. The system needed to fit into limited floor space, maintain a 2-hour replenishment cycle, and eliminate human error. Additionally, it had to deliver consistent throughput, minimize downtime, and guarantee zero-defect output without relying on manual inspection.
The Opportunity
The client required a compact, efficient, and high-precision machine to automate the assembly of two bracket variants. The system needed to fit into limited floor space, maintain a 2-hour replenishment cycle, and eliminate human error. Additionally, it had to deliver consistent throughput, minimize downtime, and guarantee zero-defect output without relying on manual inspection.
What We Did
We designed and delivered a portable, standalone Bracket Assembly Machine built for flexibility and long-cycle autonomy. Key components and features included:
- A fail-safe Poka-Yoke system to automatically manage two bracket variants without operator error.
- A 4-position rotary indexer engineered for smooth, high-speed transitions between assembly stations.
- A step feeder system for stable, low-downtime pin delivery.
- A servo- and pneumatic-driven 3-axis gantry for precise and efficient pin pick-and-place operations.
- A rotary pick-and-place unit for reliable and continuous bracket loadingA 2-axis pneumatic system for seamless molded part handling.
- An automated NG/OK segregation unit, ensuring 100% rejection of defective parts.
Each sub-system was engineered for modularity, performance, and zero-defect output.
What We Did
We designed and delivered a portable, standalone Bracket Assembly Machine built for flexibility and long-cycle autonomy. Key components and features included:
- A fail-safe Poka-Yoke system to automatically manage two bracket variants without operator error.
- A 4-position rotary indexer engineered for smooth, high-speed transitions between assembly stations.
- A step feeder system for stable, low-downtime pin delivery.
- A servo- and pneumatic-driven 3-axis gantry for precise and efficient pin pick-and-place operations.
- A rotary pick-and-place unit for reliable and continuous bracket loadingA 2-axis pneumatic system for seamless molded part handling.
- An automated NG/OK segregation unit, ensuring 100% rejection of defective parts.
Each sub-system was engineered for modularity, performance, and zero-defect output.
The Outcome
The Bracket Assembly Machine successfully delivered on all performance metrics:
- Compact, portable design enabled quick integration and repositioning within the facility.
- Zero-defect assurance through fully automated quality segregation.
- High-speed, uninterrupted operation with minimal manual intervention.
Reliable variant handling without the need for tool changes or reconfiguration
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