Industry Pain Points
The traditional manual insertion the problems of low assembly efficiency, poor line balance and high manual dependence, which makes it difficult for enterprises to cope with large quantities of orders. Non-standard product production process tracking difficulties.
Therefore, we launched a fully automatic insertion machine to improve production efficiency and quality control.
The insertion accuracy (such as the theoretical insertion speed of 0.16 s/point) is improved by automatic equipment, and the manual operation error is reduced.
Realize the linkage of intelligent warehousing system and production line, optimize the efficiency of supply chain collaboration, and shorten the delivery cycle.
Scheme design
Modular hardware layout
The design adopts block stacked structure, and divides the function modules such as rack assembly, electrical component installation and debugging area to reduce the problem of equipment interference hole.
Support special-shaped insertion machine customization, adapt to LED, automotive electronics and other industries production needs.
Intelligent Integration
Integration of PLC control, AGV logistics system and cloud monitoring platform, to achieve automatic loading and unloading and closed-loop production.
Through the lightweight touch screen to simplify the operation interface, reduce the cost of staff training, improve the efficiency of human-computer interaction.
Process optimization
Secondary processing standards: after plating hole slot cleanliness, heat treatment process strict control, to ensure the assembly accuracy.
Sensor and high-precision cylinder are introduced to improve the anti-vibration ability and frequency characteristics of the insertion and prolong the service life of the equipment.
Implementation steps and process analysis
Identify production line bottlenecks (e. g. Line balancing rate less than 65%) and develop phased assembly and commissioning plans.
Outsourcing parts dynamic tracking: through the ERP system to monitor the electroplating, chamfering and other secondary processing progress.
Assembly and commissioning
The assembly of the frame, the bottom plate, the sensor and other components is completed step by step, and the matching degree of the holes is verified by manual debugging.
Through the PLC program to optimize the timing of action to achieve a smooth transition from manual to automatic.
Validation
Comparison data: THT insertion machine line balance rate increased to 90% , single line capacity doubled, defective rate decreased by 30% .
Output standard file: contains SOP operation manual, maintenance guide and fault response process.
Iv.
Presentation of results
Improving efficiency and quality
The DIP insertion machine saves 1656 seconds per day, and the production cycle is shortened by 25% to meet the large-scale delivery needs of products such as fast charging sources.
The consistency of components is improved, the anti-vibration performance of products is enhanced, and it is suitable for high-demand scenarios such as automotive electronics.
Cost Optimization
The labor cost is reduced by 30% , the material loss is reduced by 18% , and the equipment failure response time is reduced by 40% .
Through the intelligent storage system to achieve dynamic management of spare parts inventory, reduce capital occupation.
Industry value
The formation of reusable whole line design standards, covering mobile phone chargers, LED lighting, home appliances, industrial equipment instrumentation, and other categories of production.
To promote the"Smart + quality" upgrade, cooperation customers include Guangbao Electronics, Huafeng Electronics and more than 30 Head Enterprises
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