Automated Assembly Solutions
Optimization of Assembly lowers Production Costs
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Avdel® Automation
Technology
Avdel® offers a wide range of semi and fully automated installation equipment
to suit all our customers’ requirements. All Avdel® automation equipment
is tailored to meet the specific demands of a particular environment whether
it be a small semi-automated feed system or fully-automated assembly line
for a large Automotive OEM.
In times of strong cost pressure these machines offer important benefits
due to optimized assembly processes and the associated potential savings.
Avdel® approaches the whole assembly, because there is the largest potential
for rationalisation. In fact the actual fastener cost has only a relative
small part in the total cost of the assembly.
Contact your local Avdel® representative
to discuss our Automated Assembly Solutions.
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Total Cost of
Assembly
The cost of any assembly consists of the cost of the consumable components
and the cost of the process itself. In most cases the process costs far outweigh
the piece part fastener costs – often with a ratio as high as 4:1.
Choosing the most appropriate installation system allows for the optimisation
of the process by focussing on:
Elimination of secondary operations
Using the most effective system can reduce the amount of necessary labour
or eliminate the need for it altogether; using ergonomically designed
workstations can also improve operator efficiency and hence reduce problems
related to error or fatigue.
Improved quality
Automated systems are ideal for maintaining consistency and repeatability
and reducing process variation, rework and scrap. Using integrated sensing
and process monitoring allows Avdel® equipment to verify that the fastener
has been installed every time.
Increased throughput
Automated assembly can be used to dramatically increase process throughput.
This has the benefit that our customers are able to grow their businesses
without by increasing capacity without the addition of extra resources such
as labour or floor space.
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Assembly System
Design
In helping the customer select a system our application engineers have a
wealth of experience to draw upon.
In general, the key factors in the selection are:
Process speed
The rate at which components need to be assembled will determine the type
of equipment and the number of stations needed. Ergonomic design of these
workstations, component handling systems and in built fixturing can all improve
process throughput as can the introduction of robotics and linked cells.
Flexibility
Assembly automation is not only suited to continuous flow production of a
single product type. Our systems can be designed with in built flexibility
to allow for changeovers with the minimum of unnecessary downtime. Avdel®
also offers an extensive range of handtool based solutions which offer the
greatest level of flexibility.
PLC control and monitoring
In many cases, modern manufacturing demands an increased level of process
monitoring and control. Sensors, counters and mechanical locks, tied in to
a PLC control system, give the user an increased level of confidence in the
assembled product quality. Systems can also be designed to help with preventive
maintenance regimes as well as troubleshooting any potential problems –
these can significantly the overall cost of ownership and increase the equipment
life.
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Types of Assembly
Systems
Avdel® offers different levels of automation to match the operational
requirements of the customer. These are developed using modular design principles
to:
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Improve maintenance and serviceability
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Reduce implementation times
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Increase flexibility for equipment modification and extension
Assembly stations are either designed for single riveting or allow, as multi-head
riveting station, the simultaneous fastening of multiple components in one
operation. They are independent workplaces that can easily be integrated
into existing processes. The high flexibility is due to the Avdel® platform
strategy and the modular design. The conception for each application is carried
out according to customer requirements. Depending on the application a variety
of different riveting systems can be applied. Even a combination of blind
riveting and self-pierce riveting systems is possible.
| Single-head Workstations
The single riveting stations are ergonomic small workplaces where the riveting
tool can be operated suspended, in a linear moveable tool stand or built
into the workplate. Actuation is feasible by hand release or by a foot pedal.
Single riveting stations can be optionally designed as stand or seated
workstation. The simple handling supersedes a time consuming training of
the employees.
Example
An example of a single Speed Fastening® riveting station with rivet process
monitoring. After inserting the components the take-up device locks automatically
and releases the completed assembly only after the rivetings had been carried
out at all specified fastening points. |
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| Multi-head Assembly Stations
Multiple riveting stations increase productivity and output by simultaneous
installation of several fasteners. Compared to the manual riveting the assembly
is far faster. The user only handles the components, and integrated component
fixturing provides a fast and exact positioning of the components. Twisting
does not occur because all rivets are placed at the same time. Tolerances
are maintained and finally the quality of the end product is increased. Due
to the use of the quick Avdel® Speed Fastening® technology the assembly
process obtains an additional optimization.
Example
A multi-head station with two riveting modules is shown in this example.
The riveting pitch can be continuously adjusted. The compact machine uses
the Avdel® Speed Fastening® technology, which allows continuous assembly.
The machine provides the blind rivets automatically out of the magazine.
Due to the foot release the hands stay free for component handling. This
assembly station can be designed as stand or seated workplace, ESD construction
is an option. |
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| Automated Assembly Stations
Avdel® automated assembly stations are designed for the use in automatic
production processes. The machines are modular built and the single components
are linked by flexible, plug-type connections. The rivets are transferred
via the blow feed unit. During operation processing diagnostics of all functions
can be provided by sensors. All parameters are shown on a clear and simple
control display. The modular design allows a high reusability during component
modifications or model change.
Example
In this assembly station 12 blind rivets are placed simultaneously. The rivets
are fed automatically. Positioning devices can be omitted, because the presented
rivets serve as component take-up. By using this machine the assembly time
was reduced by 75 %. |
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