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Automation

reliability - cycle after cycle

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Automation

Automated solutions can reduce your time to market, tooling costs and resources associated with multiple facilities. Tooling Tech Group offers a comprehensive line of secondary downstream solutions from semi-automated cells to those incorporating complex robots.

We design our automated solutions to perform all functions in a reliable manner, cycle after cycle. In addition, your operators will find our intuitive machine controls and programing very easy to use and operate, while the machine itself is designed to promote a safe work environment for the employee.

We’ve developed solutions for trimming, drilling, welding, routing, bonding, quality inspection, to name just a few. We invite you to contact us regarding any of your upcoming secondary equipment needs and let us show you how the right people with the right experience can make the right equipment a reality. Below you will find examples of the solutions we have developed over the years.

ASSEMBLY & CHECKING STATION

We supplied our customer with a solution for welding two components together, where clinch nuts were already pressed in prior to welding. After welding, manual processes included the insertion of two push pins for a wiring harness operation and the application of a piece of double-sided tape. However, 10 – 15% of the components were being sent to quarantine due to missing parts.

Our automation group developed a fixturing station for assembly and a checking station to verify part presence. Once the part is welded, it is manually moved to the assembly station where the pin and tape are put in place. The part is then moved to the checking station where the part is clamped in place, and it goes through an automated checking cycle. Using a variety of sensors, the presence of the tape, clinch nuts and pins are all verified. This has saved the customer about $10,000/week.

Hot Plate Welding

Hot Plate welding is widely used for plastic part assembly with high strength weld requirements. Tooling Tech Group manufactures automated hot plate systems for single layer and multi layered fuel tanks, including multiple parts per weld cycle. The design of the equipment is based on rigid construction with detailed melt control to ensure repeatability of part quality in production.

From manually loaded and unloaded machines to semi and robot automated systems, we offer qualified engineering support to accommodate your product development.

Typical hot plate welding applications include:

  • Fuel Tanks
  • Reservoirs
  • Taillight Lenses
  • Ductwork

ULTRASONIC WELDING ASSEMBLY

Tooling Tech Group utilizes state-of-the-art robotics and ultrasonics to assemble acoustic fabrics to molded thermoplastics. The universal combination of robotics & ultrasonics quickly executes multiple welding positions on complex attitudes to eliminate the need for dedicated precision weld devices at each location. Our professional engineers also design and manufacture these work cells to be interchangeable for the next application

Robotic Deflash Cell

Tooling Tech’s four-station robotic deflash cell eliminates the need for multiple stand-alone trim machines or manual operator deflash stands. Running up to four components at once, the cell utilizes a force-compliance device to mimic the human touch, precisely following parting lines and compensating on-the-fly for part shrink and variation. The system can quickly exchange one next plate for another while the robot continues to process other parts as they are loaded/unloaded. Once the new nest plate is mounted in place and the electrical connector is attached, the cell automatically identifies the new plate and loads the appropriate cutting path in the robot controller.

In addition, a Segen quick change tool adaptor on the robot end of arm allows for unlimited additional operations within the cell. Need to drill, tap, cut, or rout holes, slots, or openings in your parts? Need to attach or assemble components, screws, or any other hardware to your parts? Simply add the necessary tool with the matching quick change adaptor to the robot cell and instantly eliminate the need for a separate secondary fixture or manual operation.

ROBOTIC DRILL, ROUTE & JOINING CELL

Our customer needed to produce two versions of a composite automotive part that required the routing of 100 holes and the application of 65 float nuts along with some rivet studs. In addition, they wanted a fully automated solution with +​0.25mm tolerance on the holes, zero dust emission and a cycle time of just over three minutes. The customer thought it would take four machines to accomplish this.

Our automation team developed a solution that could route all the holes in a single orientation during a continuous process while using a minimum amount of floorspace. The process starts with the operator manually loading the part on a wall fixture where the automated cycle then starts. The part is clamped in place, the part style verified via a sensor, and several holes are drilled. The wall then rotates 180 degrees and a handling robot picks up the part and places it into the route cell where four robots cut about 65 holes. Each robot has a vacuum unit at its head and collects the dust during the routing process.  

The handling robot then moves the part to the rivet nut station where two robots apply 66 float nuts, fed to the robots via a pneumatic tube. The nuts go in and are crimped using amperage as an indicator if the nut is properly secured. At the end of this process, all six robots communicate with the material handling robot to determine good or bad part.

ROBOTIC HEAVY TRUCK SINGLE CYCLE BONDING STATION

In this process, the heavy truck components (about 5-ft x 7-ft in size) are kept in a glue/bond apply station where a robot travels along a shuttle applying the adhesive to the different stations. The operator then manually loads the components in the front half of the cell and six components on the other side of the cell. The side with six components pivots up and is merged with the stationary side with the three components. The cycle then starts where cylinders are engaged to apply the pressure to finalize the bond.

Robotic Staple Station

Our automation group utilized the flexibility of a six-axis robot to rapidly staple and assemble plastic components. A precision CNC-cut aluminum nest with replaceable, hardened, staple receiver inserts allows for repeatable part location.

The robot installs each staple then verifies it was properly driven and located before moving to the next point. A fiber optic sensor continuously monitors the amount of staples present in the gun. When the staples run low, the robot finishes processing its current part then re-orients itself to an ergonomic reload position, allowing the operator to refill the gun with a minimum of machine downtime. Interchangeable nest plates allow for unlimited part combinations for future applications.

Robotic Vision Systems

The high-tech combination of robotics and vision leveraging the short wavelength characteristic of the blue LED light makes an ideal choice for high precision dimensional measurements and many other demanding assembly applications. Image processing converts a target image captured by a Charged Couple Device (CDC) camera into a digital signal and then performs various calculations on the signal to extract the characteristics of the target.

Finally, a GO/NO-GO result is output based on preset tolerance limits. Robotics is the premier choice of operation because of its ability to quickly position itself into multiple areas to be analyzed.

Some of our valued customers

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For more automation information, fill out the form or give us a call at: +1 (937) 295-3672