Inside the product

Intelligent coding for the control of every detail

Cosberg presents a plant composed by a free-pallet line with different workstations for the assembly of valves and by special robotic equipment for their testing.

Bruna Aleramo

Precision and flexibility
The single workstations of the free-pallet line are dedicated to the feeding, the selection, the orientation and the loading of a part that will compose the valve. They are “universal” stations since they allow managing automatically, without changeovers, the 6 product variants. The free-pallet line is characterized by pallets with intelligent coding.

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All under control, even the slightest detail
The plant peculiarity consists in feeding and handling workpieces with small sizes and thin thickness, such as special washers and O-Rings with 3 mm-diameter or leaf springs with 0.1 thickness. The feeding and the orientation of so small and subtle pieces have been made possible by electroresonant feeders with Moxmec piezo-technology and by the CNC-executed selections.
The components that cannot be fed by feeders are loaded by automation systems with collection from trays and handled with Moxmec electrical axes.

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Also rejects are smart
Each component, before being mounted on the valve body, must be checked; if an operation is defective, thanks to the smart pallet coding, the piece prosecutes without stopping in other posts and is unloaded into rejects. Rejects are then subdivided according to the error registered for the sampling control in lab and for the piece recovery.

One of the presses

One of the presses.

Robot with vision system.

Robot with vision system.

QUALITY IN NUMBERS
Pieces automatically assembled: 11
Product version: 6
Machine set up time at the changeover: immediate
Assembling and testing cycle time: 1 piece every 20”

WHAT WE FIND IN THE PLANT
4 tele-cameras that control the piece integrity, piece tolerance measures, orientation and post.-assembly position of the same in the valve body
3 electrical presses managed by piezo-electrical technology to grant precision, repeatability and speed used for the driving of some components inside the valve body with ±10 micron positioning tolerance. Thanks also to a loop system with linear transducers and measuring cameras, we can grant these tolerances, even if the components have been manufactured with 0.1 mm tolerance. Control of coil integrity and correctness depending on the set product code.
2 robot: a robot picks the coil from a tray, positions it under a tele-camera to verify the product integrity and the contact parallelism before proceeding to the insertion of the coil into the valve body; the second robot is used to automate the testing isle and to palletize the finished product. Bonding station with dispenser. After the bond dosing, the valve translates into a polymerization station of the bonding agent through UV led lamp. Laser for marking the logo and the serial number of the valve
3 Flow rate and sealing controls for the valve testing. Cosberg system for the monitoring of production data, with statistical processing and downtime analysis

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