Master Cylinder & Hydro-booster Assembly
Background:
A recent client is a leading supplier of brake systems in the world. They specialize in fields ranging from individual components up to complete braking systems. This client comes to Edgewater Automation when they need custom automation for master cylinders, disc brakes, and hydro-booster braking systems.
The Challenge:
Our client was attempting to assemble master cylinders to hydro-boosters all in one unit and at a single station. They were having problems matching production requirements because of efficiency at the original station. A single operator was required to manually lift the materials, bolt the components together, and test them to make sure there weren’t any leaks.
Our client needed to automate this process because they needed to reduce the 104 second cycle time.
The Solution:
Edgewater Automation built an automated four station assembly and test machine that is custom designed for their specific needs. The new line was designed to balance work loads between the 4 stations and improve ergonomics.
The first station puts the master cylinder and the hydro-boost together, and tightens the two screws to ensure the components are properly in-place.
The second station installs and tightens the 3 tubes to the bracket clamp.
The third station tightens the tubing to the hydro-boost assembly.
The fourth station puts a barcode labeler on the master cylinders’ tank, as a cognex camera checks it to make sure it is visually readable. The seal is tested in the hydro-boost chamber to make sure there aren’t any leaks.
After the master cylinder and the hydro-boost have been successfully assembled and pass the leak test, then the assembly is pack-out for shipment. The now empty pallet is returned back to the original operator via a flat belt conveyor in the rear of the station.
Benefits:
By automating this assembly and test process, Edgewater Automation has offered its client the ability to increase their production by decreasing assembly time in material handling and fabrication.
