A flexible robotic production cell solution, has been delivered to Deutsch UK by robotics and automation specialist Aylesbury Automation. The robot-based machine has been introduced as a result of increasing product demand. It assembles a range of similar, two pin electrical plugs and sockets and produces one complete part every six seconds.

Matt Davidson, Production Engineering Manager at Deutsch UK says, “The new machine is excellent. We’ve had it running in production ever since commission. It is extremely reliable and the amount of operator adjustment necessary has been far less than we expected.”

Deutsch UK, a specialist manufacturer of interconnection equipment for harsh environments, required a flexible solution to match its process requirements at its manufacturing plant at St Leonards on Sea. By replacing a conventional rotary table with a robot, when product changes demand, Deutsch is able to reprogramme the machine instead of investing in new tooling. Robots in manufacturing require shorter lead times than conventional solutions with less mechanical parts requiring change when lines and processes are altered.

Plug caps and bodies are ultrasonically welded in a single assembly fixture by the Aylesbury Automation production cell. Two vibratory bowl feeders and linear drivers feed the parts into the machine. The bowls and linear tracks have been tooled to orientate the parts into the correct position to be picked up by a DENSO HS 45352G robot supplied by AA Robotics, the robotics division of Aylesbury Automation. Flexible design of the machine means that different similar components - where there is a change in shape of plug and socket body - can be accommodated very easily, by interchangeable bowl tops and linear feeder tracks.
The robot loads the parts under a Branson ultrasonic welder, after which a stamp is applied to some of the caps. A quality assurance, tensile (pull) test is made on selected products and the frequency of this testing is controlled by the customer, from the robot’s HMI panel.

There is no PLC in the production cell. All the machines functions are coordinated by the multi tasking robot controller using Devicenet I/O and this solution brings considerable cost savings. Six background tasks operate to control 128 I/O points and all status and error messages are shown on the robot HMI.

Deutsch has been using a robot for some time in the manufacture of products but, encouraged by the low capital cost of the Aylesbury Automation solution, the company is now exploring other processes which might benefit from robotic solutions.

“I’ve been most impressed with the the machine supplied to us,” says Matt Davison. “It has been running consistently in production since it was commissioned with products being manufactured and packaged directly into their shipping cartons. I hope this will be indicative of future equipment supplied by Aylesbury Automation as this has been a most successful project.”

Aylesbury Automation, a system integrator for AA Robotics DENSO robots, is the UK`s leading supplier of productivity solutions to the manufacturing sector with over 48 years experience gained throughout almost every type of industry. The company’s core products include a full range of tooled vibration parts feeders, associated handling equipment, robots and rivet setting machines, enabling a complete and often turnkey service to customers. The business runs a full IT capability, using networked computers and sophisticated SolidWorks 3D CAD system and is ISO 9001:2008 and Investors in People accredited. Aylesbury Automation employs approximately 25 people at its UK headquarters and manufacturing plant located in Aylesbury, Buckinghamshire.

Have you a requirement?

Should you have any potential problems or projects you wish to discuss, then one of our sales application engineers will be willing to visit you on site to give assistance. Alternatively, you are most welcome to visit our company at Aylesbury to view our premises and to discuss your particular application.

Aylesbury Automation is accredited to ISO 9001:2008 and Investors in People.

For further information, advice and customer services, contact:
The Sales Department
Aylesbury Automation Limited
Unit 2 Farmbrough Close
Stocklake Park
Aylesbury
Buckinghamshire
HP20 1DQ

Telephone: +44 (0) 1296 314300
Fax: +44 (0) 1296 482424
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