Ch 17 Automated Assembly Systems

Sections:
1. Fundamentals of Automated Assembly Systems
2. Quantitative Analysis of Assembly Systems

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 Automated Assembly - Defined

The use of mechanized and automated devices to perform

the various assembly tasks in an assembly line or cell
Fixed automation usually
Most automated assembly systems are designed to
perform a fixed sequence of assembly steps on a
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 Automated Assembly -
Application Characteristics
Where is automated assembly appropriate:
High product demand
Stable product design
The assembly consists of no more than a limited
number of components
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 Typical Products

Alarm clocks Light bulbs

Ball bearings Locks
Ball point pens Mechanical pencils
Cigarette lighters PCB assemblies
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 Assembly Processes in
Automated Assembly

Adhesive bonding Snap fitting

Insertion of components Soldering
Placement of components Spot welding
Riveting Stapling
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 System Configurations

1. In-line assembly machine

2. Dial indexing machine
3. Carousel assembly system
4. Single-station assembly cell
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 In-Line Assembly Machine

A series of automatic workstations located along and in-line

transfer system
Either synchronous or asynchronous work transfer used

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 Dial Indexing Machine

Base parts are loaded onto

fixtures or nests attached
to a circular dial table,
and components are
added at workstations
located around the
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 Dial indexing
assembly
machine
(Bodine
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 Carousel Assembly System

A hybrid between circular work flow of dial indexing machine

and straight work flow of in-line system

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 Single-Station Assembly Cell

Assembly operations are performed on a base part at a

single location
A robot is sometimes used as the assembly machine

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 Multi-Station vs. Single-Station

Multi-station assembly machine or line

Faster cycle rate
High production quantities
More operations possible
More components per assembly
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Suited to
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 Parts Delivery at Workstations

Typical parts delivery system at a workstation

consists of the following hardware components:
1. Hopper - container for parts
2. Parts feeder - removes parts from hopper
3. Selector and/or orientor - to assure part is in
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 Parts Delivery System at Station

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 Vibratory Bowl Feeder

Most versatile of hopper feeders for small parts

Consists of bowl and helical track
Parts are poured into bowl
Helical track moves part from bottom of bowl to outlet
Vibration applied by electromagnetic base
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 Vibratory Bowl Feeder

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 Vibratory Bowl Feeder

Photo courtesy
Syntron Inc.

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 Selector and/or Orientor

Purpose - to establish the proper orientation of the

components for the assembly workhead
Selector
Acts as a filter
Only parts in proper orientation are allowed to pass
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 Parts Selection and Orientation

(a) Selector

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(b) Orientor
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 Feed Track

Moves parts from hopper to assembly workhead

Categories:
1. Gravity - hopper and feeder are located at higher
elevation than workhead
2. Powered - uses air or vibration to move parts toward
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 Escapement and Placement Devices

Escapement device
Removes parts from feed track at time intervals that are
consistent with the cycle time of the assembly
workhead
Placement device
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 Escapement and Placement Devices

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 Escapement and Placement Devices

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Escapement
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 Escapement and Placement Devices

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 Quantitative Analysis of
Assembly Systems
1. Parts delivery system at workstations
2. Multi-station assembly machines
3. Single-station assembly cells
4. Partial automation
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 What the Equations Tell Us

The parts delivery system at each station must deliver

components to the assembly operation at a net rate that is
greater than or equal to the cycle rate of the assembly
workhead
Otherwise, assembly system performance is limited by
the parts delivery system rather than the assembly
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 What the Equations Tell Us

As the number of stations increases, uptime efficiency and

production rate are adversely affected due to parts quality
and station reliability effects
The cycle time of a multi-station assembly system is
determined by its slowest station
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Nouptime
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 What the Equations Tell Us

Multi-station assembly systems are appropriate for high

production applications and long production runs
By comparison, single-station assembly cells have a
longer cycle time and are more appropriate for mid-range
quantities
Storage
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