Overview:

The OPBH Final Assembly System is a three-cell in-line assembly system, built around a Bosch TS1 pallet conveyor system. The system was developed as a downstream cost savings system for the OPBH Automated Assembly System. The system consists of three cells -- a performance tesing cell, a final component installation cell and a cell to unload and organize the finished assemblies on trays.

Process Description:

Brush heads are removed from the OPBH Automated Assembly System and placed individually into fixtured TS1 pallets.  The pallets are carried on the conveyor system through each cell.

At the first cell, the brush heads are removed from the pallet by a Seiko SCARA robot, and placed into one of three dynamic testing devices. As each test fixture is loaded, the fixture slides back under a clamping device, which clamps the brush head from above, as it would be used in the real product. The brush head is then driven at the intended drive frequency, and the dynamic amplitude is measured with a Keyence LC-5450 ultra-high accuracy laser displacement meter. The peak amplitude is compared to an acceptable range, and either replaced in the pallet for subsequent processing, or discarded into a bin for failure analysis.

At the second cell, two additional components are attached to the tested brush head. Neither represents a functional component of the device, and are only attached after testing to reduce potential scrap costs. Both components, the nut and the travel cap, are fed from a horizontal tube feeder, and presented to a SCARA robot for installation.

At the final cell, the brush heads are removed from the pallets and arranged ona magnetic tray for transfer to a downstream system for automatic packaging.  The brush heads are arranged in a matrix format.