The project included the design, manufacture and commissioning of two facilities for the assembly of Front and Rear Subframes for the North American market.
The assembly line concept included two different machines: a first semi-automatic robotized cell for the pressing of bushes in rear subframe and a second manual station for the screwing of two components that form the front subframe.
Due to the specific production requirements for this project, we selected a combined solution of automatic assembly process and manual loading of components, optimizing the work of the cell operator focused on the material supply process.
The designed machine, based on the concepts of flexibility in the assembly through the use of robot for the positioning of parts, includes all the traceability and process data recording in order to guarantee the quality of the finished product, thus complying with the demanding requests of our customer.
The part assembly process is performed as follows:
- A first robot carries out the loading of the components from the manual table to the pressing station.
- The second robot presents the part in its different pressing positions.
All pressing processes are carried out by means of an electric press, controlling the force and insertion height parameters to guarantee the result according to the customer's requirements.
The project includes a second machine consisting of a manual station where an operator performs both the work of loading / unloading parts, as well as the screwing with electric screwdrivers.
During the front subframe loading operation, the operator uses a handheld 2DM reader to identify the part and associate the tightening data along with the rest of the parameters registered during the manufacturing process.
Customized solutions according to the part to be conveyed, its size and required orientation.
- Palletized conveyors
- Roller chain conveyors
- Belt conveyors
Solutions adapted to customer's process / lay-out requirements:
- Separated input and output conveyors
- Conveyor loops including curves
- Palletized conveyors with lifts at each end and two height lanes
We have the capacity to integrate standard third-party equipment as well as conveyors of our own design. Our product development includes pneumatically actuated stoppers of proprietary design.
When talking about automatic loading / unloading of our machines, integration of six axes and cartesian robots becomes a guarantee for high efficiency solutions.
We have wide experience in integrating robots of various brands, not only for handling purposes but also as a key tool in some of our assembly standarized solutions.
Design and integration of in-house designed grippers (EOAT), adapted to the needs of each application.
Simulation services for the entire robot cycle to assure the process in cycle time conditions and to avoid possible collisions or interferences.
Within the operations related to traceability, and especially after marking the parts on the machine, it is necessary to check the correct marking or to incorporate the unique part ID to associate the process data to the part.
Integration of cameras or sensors for 2DM code / QR / Barcode reading.
Possibility of marking degree evaluation according to the ISO/IEC TR 29158 (AIM DPM-1-2006) standard, by means of special verification units.
In order to respond to the traceability needs of our customers, at Gaindu we have developed our own software called Gaindu Tracker, with which we provide our installations with the functionality to record process data associated with unique part IDs.
We integrate industrial PCs from leading manufacturers as hardware support for our customized software development.
Complete collecting of data related to the process:
- Leak test values
- Insertion forces and positions
- Torque and anglel values
We study each project in detail in order to adapt to the existing IT systems in our customers' plants, integrating our machines in their information networks.
Monitoring of the assembly processes for component pressing, controlling the parameters during the whole cycle.
At Gaindu we have installed more than 300 electric presses with which we have assembled all types of parts and units. Assembly processing of engines, suspensions, gearboxes, etc...
We are the official distributor of JANOME electric presses in Spain, having collaborated with them directly in the validation and expansion of assembly processes using electric presses.
Following our vocation of customer-oriented solutions, we adapt to the approved brands and preferences of our customers when designing our installations. This has led us to work with the leading global manufacturers of electrical presses and gives us the advantage of being able to offer our solutions integrating reliably any of these brands.
Possibility to perform tightening operations using electrical screwdrivers, controlling the applied torque and final angle on the process.
Simpler tightening / untightening operations could also include pneumatically driven tighteners or tailor made untightening electromechanical units.
We adapt our assembly solutions to our customer's need, integrating on that purpose their preferred electrical screwdriver brand.
Union of components using all type and sizes of bolts, screws, thread plugs, etc…
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