HEITEC Slovensko implemented a semi-automatic production line for a major automotive supplier for the assembly and testing of special parts that control the charging process in electric cars.
As the system is designed, it’s first loaded manually by the operator: They have several access points to all eight stations for this purpose and for cleaning. Following loading, a precise quantity of a special heat-conducting paste is applied to the parts and checked for accuracy by a 3D image processing system. In the next step, printed circuit boards are inserted, and after the connections are wired they’re bonded with the parts and rechecked by an industrial camera system. Covers are then welded on using an ultrasonic welder. A high-voltage test is performed as along with label printing for the end product prior to a function test. The operator then manually loads the system.
The individual steps required for producing the part were interlinked in this semi-automatic system. The work time per part is only 45 seconds, corresponding to a production line output of 74 parts per hour. With the help of a convenient user interface, the plant can now be operated in both automatic and manual mode for full flexibility in the production process. Thanks to the image processing systems implemented, entire process steps are recorded and stored for a track & trace analysis. This guarantees the customer full traceability as needed.
In terms of technology, all the requirements for the project were optimally met. Because the steps are automated and interlinked, just two operators are required instead of nine, allowing the customer to effectively reduce their personnel costs for manufacturing the part. Production output was also increased to 533 units per shift. They can now produce more parts in a shorter period of time, with a lower reject rate and a higher-quality end product.
As a general service provider, HEITEC supplied everything from a single source – from planning, construction, and commissioning to total flexibility in planning and organizing warranty services and customer service activities. Ultimately, we effectively contributed to boosting the customer’s productivity and increasing the quality of their end product.
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