Overview:

The Ferrite Installation Cell uses a pneumatic pick-and-place device to install ferrite cores during appliance assembly. The ferrites are pushed onto a plastic boss which is subsequently thermally staked.

Process Description:

Ferrites are fed into a gravity-ramp using a standard bowl feeder.  The gravity ramp ensures a constant back pressure on the feed stack, and provides immediate replenishment at the pick point, maintaining cycle rate.

The ferrite is picked using a electromagnetic gripper, which holds the ferrite in a shallow cavity.  The AFAG pneumatic pick-and-place executes a simple up-over-down cycle, pressing the ferrite onto the retention boss. The AFAG device allows independent precise setting of the pick and place points.  When the ferrite is properly nested, the electromagnetic gripper is released, and the cycle is repeated.

Technical Challenge:

Creation of a custom electromagnetic gripper that could fit within the assembly cavity was a challenge.  The ferrite was essentially installed at the bottom of a long dark hole. The electromagnet had to fit within that hole, and initial attempts failed to create sufficient holding force to keep the magnet in the gripper. Ultimately, the magnetic strength of the gripper was improved with the use of thicker wire, more current, an iron core and a substantial increase in length.