Truck Bed Lamp Assembly & Test Machine

This cell had to assemble (5) parts into (1) Truck Bed Lamp Assembly every 10 seconds or less. Vibration welding took 30 seconds to complete, so in order to meet the goal of a 10 second machine cycle time, (4) Truck Lamp Assemblies had to be welded at the same time. Each part was tested at 1.0 psig pressure decay with 12VDC. Light color and intensity met current limits of 164 mA +/- 15% mA. Production data was retrieved from the PLC through the HMI. This included recording date code or fail code being laser etched to the housing for traceability. Scrap and system failure rate had to be 1%, this meant removing the human element from the assembly process. A cabinet tray feed system was developed to allow the operator to load and unload the parts outside of the work area, allowing the robot to continue picking parts from another tray in the work area.