PCB Flex Cable Insertion using Epson N2 and FT Sensors

Industry > ElectronicsApplication > AssemblySector > Manufacturing

This assembly automation solution utilizes the Epson N2 robot and FT (Force-Torque) sensors to automate the highly difficult process of inserting Flex Cables into PCB connectors.

It is the optimal solution for performing high-precision assembly tasks while minimizing cycle times within confined workspaces. This project was initiated to automate the Flex Cable insertion process, which previously relied entirely on manual labor.

Components

Robot	Robot: EPSON N2 (6-Axis Articulated Folding Arm) Unique Design: Innovative folding-arm structure that reduces the workspace footprint by approximately 40%. Payload: 2.5kg (Rated: 1kg) Reach: 450mm Weight: 19kg Repeatability: ±0.02mm Force Sensor: Integrated FT sensor for real-time tactile feedback during insertion.

Workflow

STEP 1.	Loading: The robot picks the PCB and places it into a fixed assembly jig.
STEP 2.	Preparation: The robot opens the Flex Cable connector clip on the PCB.
STEP 3.	Pre-alignment: The Flex Cable is picked and placed onto an alignment jig.
STEP 4.	Precise Insertion: The aligned Flex Cable is re-picked and carefully inserted into the PCB connector using force feedback.
STEP 5.	Locking: The robot closes the connector clip and proceeds to the next cable.
STEP 6.	Unloading: Once all cable insertions are complete, the PCB is moved to the finished goods rack.

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Features

High-Precision Insertion Performance

Micro-Force Sensing: Utilizes an FT sensor capable of detecting forces as small as 0.1N / 0.003Nm to verify successful cable insertion and perform delicate tasks.

Smart Error Correction: Automatically detects and compensates for socket position errors, tilts, or misalignments by sensing the direction of applied force.

Reliable Connector Entry: Leverages high repeatability to insert thin Flex Cables into ultra-narrow connector housings without failure.

Damage Prevention: Precise force monitoring prevents mechanical stress, protecting both the fragile connectors and the flexible cables from breakage.

Tolerance Management: Accommodates geometric variations between parts by dynamically adjusting the insertion force in real-time.

Ultra-Compact Installation

Ceiling-Mount Configuration: Minimizes the floor footprint required for robot installation.

Folding-Arm Structure: The unique N2 "folding" design significantly reduces the workspace volume needed during operation compared to standard 6-axis robots.

Minimized Cycle Time through Speed & Efficiency

High-Speed Articulation: Rapid joint speeds of up to 360°/s ensure high-throughput performance.

Optimized Paths: The folding-arm design allows the robot to move via the shortest possible path even in confined spaces, slashing overall cycle times.

Reliable Quality Assurance

Worry-Free Operation: Includes a 1-year comprehensive warranty for peace of mind.

Results

ROI Period	26.4 months
Key Benefits	Quality: Drastic reduction in cable connection defect rates. Labor: Significant reduction in manual labor required for tedious cable assembly.
Client Feedback	We initially believed that automating Flex Cable insertion would be nearly impossible. However, through this solution, we successfully automated a process that was previously 100% manual. This stands as Korea’s first successful case of automating the FPCB insertion process.