Automated line for sorting and testing PCB assemblies
In an industry where precision and repeatability are key, automated solutions are essential to optimize the production of electronic components. We present a line for handling, testing, and packaging PCB assemblies that integrates manual loading, robotic processing, and automated packaging.
Initial challenge - The client sought a solution that would enable efficient processing of sensitive PCB assemblies after injection molding. The system needed to include manual loading, automated handling using robots, functional testing, sorting of parts, and precise packaging, while ensuring continuous operation, traceability, and easy maintenance.
Result - An integrated line was established with six dedicated pallets, two robotic cells, conveyors, and an SPEA testing device, enabling stable, reliable, and automated production with minimal operator intervention.
Solution description
The automated line is a modular system connecting manual loading, robotic handling, automatic testing, and sorting of PCB assemblies in a continuous cycle. The line uses six rotating dedicated pallets, allowing simultaneous throughput of multiple PCB assemblies. Each stage operates in coordination through precise position control, photoelectric sensors, and pneumatic actuators, ensuring repeatability and traceability.
The system includes:
- input workstation with belt conveyor,
- robotic cell 1 (RC1) for loading assemblies onto pallets,
- SPEA functional testing device,
- robotic cell 2 (RC2) for sorting and packaging assemblies,
- manipulator for packaging into blisters and boxes,
- lift belt conveyor for returning empty pallets,
- intelligent logic for fault detection and response.
With the help of a camera, the processing of each part is adjusted on the fly according to its position and orientation, allowing the handling of various geometries without mechanical adjustments.
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Automated line operating process
1. Manual loading of PCB assemblies
The operator manually loads assemblies onto the input conveyor. A photoelectric sensor detects the presence of the hand and temporarily stops the belt for safe placement. Once the assembly is properly placed, the conveyor starts and stops at a precisely defined position for pick-up.
2. Picking assemblies with robot in RC1
The robot in RC1 detects the position and rotation of the assembly using a camera and accurately transfers it onto a dedicated empty pallet. The camera enables adjustment to different orientations without mechanical setup.
3. Transporting the pallet to the SPEA testing device
When the pallet is full, the system transfers it via a lifting module to the SPEA tester, where automatic measurements and diagnostics are performed on each individual assembly on the pallet.
4. Transferring the tested pallet to RC2
The verified pallet is transported to RC2. If the receiving position is free, the pallet is lifted, aligned, and prepared for pick-up.
5. Sorting assemblies based on test results
The robot in RC2 sorts the assemblies according to the SPEA results. Faultless assemblies are placed into blisters, faulty ones into a reject drawer. For traceability, the QR code is also verified.
6. Automated blister packaging
The manipulator automatically replaces empty blisters from the feeder. Assemblies are stacked in a pattern (every other rotated), up to 24 pieces per blister. When the blister is full, it moves to the pick-up position where a vacuum manipulator transfers it into a box.
7. Packaging blisters into boxes
Boxes are automatically positioned. The manipulator stacks blisters into the box; the last blister serves as the lid. The filled box moves forward for manual removal.
8. Returning empty pallets
Empty pallets return to RC1 via the upper conveyor. The system operates in a loop; protective covers disable operation when opened.