Cost-effective chain conveyor solution optimises assembly process
Task
During the production and assembly of brake callipers, continuous, reproducible and efficient transportation of the components is required. After mechanical processing, such as CNC milling, drilling or thread cutting, the components must be carefully picked up and transported in the correct position. The assembly process includes the installation of pistons, seals, sleeves, guide bolts and, if necessary, holders. This requires precise and stable positioning, both at automated and manual assembly stations.
Onward transport to the subsequent processes, such as, functional and leak testing, must also be reliably integrated into the workflow. The transport system used must be able to maintain cycle times, provide buffer zones and stop and position the pallets precisely at specified stations.
A total transport distance of around 25 meters needs to be covered. A brake calliper weighs approximately 5 kg, plus the net weight of the pallet. Therefore, a flexible and compact pallet circulation system is required which efficiently combines the above process steps.
Solution from mk
The Versaflex chain conveyor system from mk is ideal for these requirements. The system is based on a modular aluminium profile construction and is also designed for simple transportation of pallets. It enables complex route layouts in confined spaces and reliable positioning with an accuracy of ± 0.1 mm. In addition, the pallets can be buffered, stopped and precisely aligned at defined machining stations.
Due to the high load on the chain in this application, variant P11 is recommended as it has twice the chain tensile force of the compact variant P08. This enables payloads of up to 30 kg and transport distances of up to 30 m to be realized. The maximum transport speed is 30 m/min. The pallets can be selected in 250 or 300 mm widths and can be flexibly adapted to individual requirements.
The process involves a robot automatically placing the brake callipers on the pallets after machining. Within the assembly process, the work steps are either carried out directly on the pallet or the part is removed for processing and then returned to the pallet. Once assembly is complete, the brake callipers are reliably transported to the test stations via the circulation system, thereby ensuring a continuous and efficient production flow.
Customer benefits
- Cost-effective alternative to conventional multi-line pallet systems
- Modular design allows subsequent, flexible adaptation to new series, etc.
- Customized solution made from standard components individually adapted to the requirements of the assembly process
Products used
