Electronic Connector Assembly: http://robot.fanucamerica.com/Products/Robots/assembly-robots.aspx
Automation Expert and FANUC America Authorized Integrator Durabotics developed this assembly workcell to automate the process of metal contact and plastic insulator seal plug insertion into various sizes and shapes of electronic connectors. This system was specifically developed to assemble electronic connectors for the aerospace industry. However, this system can handle over 60 styles and sizes of connectors for a variety of industries. Each style and size connector can have a combination of 4 to 100 insertions of up to six different metal contacts and seal plug connectors.
The system starts when a pallet containing six connectors enters the system. Each pallet can contain all different types and sizes of connectors and these can all have different recipe combinations of contacts and seal plugs. Each pallet contains a bar code that the robotic system reads and queries a database to determine which connector styles and sizes are in that particular pallet. It also determines the recipe combination of contacts and seal plugs for each connector in the pallet.
The robot used for the assembly is the highly flexible, versatile and compact FANUC LR Mate 200iD/7L long arm robot. This robot’s custom-built end effector is very unique and consists of three major sections: A vision camera with LED ring lighting, a tool changer that allows the robot to choose a variety of four end-effectors for picking and seating, and thirdly, a universal gripper for loading and unloading the full range of connector bodies on the pallet. Once the bar code scanner identifies the pallet and its connectors, the robot camera takes a photo of the first connector to verify it is the correct connector for the recipe it has received and that it matches with its recipe database. The robot picks the connector and places it into an interlocking v-design assembly station. The robot vision system again verifies part ID and orientation, and proceeds to populate the connector with metal contacts and seal plugs according to the recipe.
The FANUC LR Mate 200iD/7L robot is picking contacts and seal plugs from any of three backlit shaker table feeders that shake and spread the parts enough to allow the robot vision system to see isolated parts. This system has three shaker table feeders, but Durabotics can expand it to six feeders, all of which can hold one or more parts and can advance, retract, flip or spread the parts. The robot controller, vision system and PLC work with the on-board PLC on each feeder to spread parts so the robot can see them.
During each pick the robot moves the part past a straightening tool to assure it is properly seated. Each part is presented to another camera and light to assure it has the right contact or seal plug, then the part is inserted into the connector until it is fully populated. Once the connector is correctly populated, the robot picks the finished connector and places it into the pallet in the same spot it was originally picked. Once all connectors in a pallet are fully populated, the completed pallet is transferred out of the system, the next pallet moves in, and the process repeats.
This electronic connector assembly system improves upon an extremely tedious, inefficient and time-consuming manual process. To learn about this system and more from FANUC America Authorized Integrator Durabotics please visit their website at http://www.durabotics.com.