Overview:

The laser tuner performs dynamic testing of brush head assemblies, trims them to adjust performance within specification, and retests the trimmed assemblies to verify compliance. The system uses a high-speed Epson SCARA robot to load and unload a rotary indexer from a pallet transfer system, a 750W Nd:YAG laser to trim the assemblies, and two lasesr doppler vibrometers to measure the dyanmic performance.

Process Description:

The incoming assemblies are loaded into active fixture nests on the rotary indexer using an Epson EC-350 SCARA robot. The assemblies are pneumatically clamped to ensure proper performance during dynamic testing.

After loading, the brush heads are positioned above an electromagnet drive station, which energizes the product at a variety of frequencies.  The dynamic response is measured at each frequency, using a laser doppler vibrometer.  The response data is then mapped to a standard to determine the trimming need to bring the head within specification.

The characterized brush head is then transported to the first cutting station, where a thin slice of stainless steel is removed from one leg of the motor spring. The removal is performed by a three-axis NC laser cutting head. A second slice is removed at a second identical station.

The trimmed brush head is then re-characterized with the second laser dopper vibrometer. Each head is replaced in a pallet by the SCARA robot, and marked electronically as passed or failed unit. Failed units are subsequently removed from the line at a downstream reject station.