Process layout
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 |
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Workflow
| STEP 1. | Loading: The robot picks the PCB and places it into a fixed assembly jig. |
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| 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. |
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
| Key Benefits | Quality: Drastic reduction in cable connection defect rates.
Labor: Significant reduction in manual labor required for tedious cable assembly.
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| 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.
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