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Aylesbury Automation has revealed how a complete robotic production cell solution has helped Autosplice Brittanic to win a contract and create new jobs.

The robot-based manufacturing system supplied by Aylesbury Automation uses the customer’s own equipment and three Denso six-axis robots to link eight individual production processes and produces a tested component every 12 seconds.

Autosplice Brittanic produces high-quality engineering components for automotive, electronics and telecommunications industries.

The company required an innovative solution for a complex requirement in the production of electrical connectors at its manufacturing plant in Ilkeston, Derbyshire, UK.

Quality improvements within tight cost constraints were essential to enable it to compete and win orders in international markets.

The solution provided by Aylesbury Automation, with robots supplied by AA Robotics, the UK distributor for Denso robots, was low in capital cost because it relies on Autosplice Brittanic’s existing equipment – a rotary injection-moulding machine and four punch presses.

To this production process Aylesbury Automation added three Denso robots and Cognex /ATEQ and HAL inspection and test stations designed by its engineers.

In order to produce the high-quality electrical connector, four accurately-punched parts and two turned parts are placed in each of four injection-mould cavities by the Denso robots.

Following the injection-moulding process the moulded parts are removed from the mould tool cavities by robot and taken through two press-trimming operations.

After the final trimming and forming operation the component is checked by Cognex vision equipment for moulding defects.

The component is then placed into a specially designed test cell where a high voltage test, vacuum test and further vision checks are completed.

Components that pass all the tests are removed from the test station and placed into a basket.

The basket, when full, is conveyed to a washing process.

There is no PLC in the manufacturing cell; all the machine’s functions are coordinated by the multi-tasking robot controllers using Devicenet I/O.

This brings a considerable cost saving.

10 background tasks operate to control 256 I/O points and all production statistics, system status and error messages are shown on the robot HMI.

This is Autosplice Britannic’s first robot manufacturing operation.

Encouraged by the low capital cost of the Aylesbury Automation /AA Robotics solution, the company is now exploring other processes that might benefit from robotic solutions in terms of quality improvement and cost reductions.

Aylesbury Automation

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