Automated Weather Strip Clip Insertion System using a Cartesian Robot

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Automated Weather Strip Clip Insertion System using a Cartesian Robot

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Application Field: Industry > Automotive, Application > Inspection, Sector > Manufacturing

Industry > AutomotiveApplication > InspectionSector > Manufacturing

#ClipInsertion#CartesianRobot#InLineAutomation#MachineVisionInspection#OKNGSorting#HighUptime#LowDefectRate#IncreasedCapacity

Process Overview

This solution is a manufacturing automation system that automates the insertion process of automotive weather strip clips using a cartesian robot.

By automating the entire continuous workflow in-line, including raw material cutting, clip insertion, and appearance inspection, productivity has been significantly improved.

Components

Robot	Cartesian robot
Peripherals	Sony machine vision system (ez-VISION) Pattern matching: Detects presence and condition of measured parts Edge: Checks part presence and assembly condition Length: Detects position and appearance defects, measures distance Histogram: Inspects contamination and print density 1D/2D barcode: Manages product lot manufacturing information OCR: Recognizes characters such as model name and expiration date Circle: Measures location and size of circular parts Color pattern matching: Color matching and comparison Edge contour: Surface inspection and defect inspection Blob: Measures area Raw material infeed feeder Cutting unit and hole machining unit Product transfer conveyor Product fixing jig

Robot

Cartesian robot

Peripherals

Sony machine vision system (ez-VISION)
Pattern matching: Detects presence and condition of measured parts
Edge: Checks part presence and assembly condition
Length: Detects position and appearance defects, measures distance
Histogram: Inspects contamination and print density
1D/2D barcode: Manages product lot manufacturing information
OCR: Recognizes characters such as model name and expiration date
Circle: Measures location and size of circular parts
Color pattern matching: Color matching and comparison
Edge contour: Surface inspection and defect inspection
Blob: Measures area
Raw material infeed feeder
Cutting unit and hole machining unit
Product transfer conveyor
Product fixing jig

Workflow

STEP 1.	Strip alignment and cutting
STEP 2.	Hole machining and clip insertion
STEP 3.	Vision inspection for hole machining and clip insertion
STEP 4.	OK/NG sorting and discharge
STEP 5.	Washing
STEP 6.	Appearance inspection
STEP 7.	Finished product discharge

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Features

Excellent production efficiency and improved quality

Improves production efficiency through continuous operation with minimized downtime
Minimizes cycle time by performing precise operations using a fast and accurate cartesian robot
Enables early detection and improvement of defects through 100% inspection of finished products
Enables easy maintenance through guides for error status and corrective actions
Reduces the required number of operators by minimizing management points

Results

Key Benefits	Uptime: 95% Defect rate: 0.5% 35 sec per unit (26 clips per strip)
Client Feedback	By minimizing downtime and waiting time, continuous production became possible and overall production capacity increased significantly.

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