Car sensor assembly and testing

Assembly and testing

This assembly and testing line of auto sensor signed Camas, is fully automatic and of the latest generation. The production line is composed of 3 rotary tables interconnected by going-and-going belts and a total of 40 working stations, which allow the production of 1200 pieces per hour.

Some of the most relevant assembly applications present on this system are:
– Hot welding
– Palletising systems for delicate components (specifically plastic components loaded from blister packs)
– Printed circuit board unwinding system
– Integration of a co-moulding system
– Laser welding of the two body shells

Line with free pallets

Particular attention is paid to the handling of the components, as they are electronic components. For this reason their feeding is mostly done through palletizing systems and the gripping is done through grippers with suction cups.

In the second part, the assembly and testing plant for car sensor consists of a free pallet line, where the sensor, previously assembled, is programmed and immediately tested in its functionality (EoL test).

Programming software

The sensor circuit programming software and the EoL test are entirely designed and manufactured by Camas.

The QR code marking is done through the use of several laser units. The QR code marked includes the serial number of the part to which all production data is uniquely associated. Through the tracking system of the components and the assembly and testing process, it is possible to retrieve all the production data of the single sensor, even in the after-sales phase.
The export of this data is completely interconnected with the company’s production system.

Vision systems

All operations are controlled by means of vision systems that verify the correctness of the components, correct assembly and final aesthetic performance.
Also in this case the programming of the vision systems is carried out entirely by Camas.

One of the successes of this complete automatic line for car sensor is the achievement of excellent production values (OEE), a result obtained through careful balancing and division of the various assembly phases first and then testing.



Main characteristics:
Two rotary tables with 24 stations each.

The machine processes both the right and left pieces. The two couplers can be produced simultaneously or on only a selected side.

Multi-model line (8 types). Piece discharge in bag packaging system.

Line composed of a pair of rotary tables with 24 dividers for complete assembly of the headrest coupler. The line simultaneously produces the right and left couplers, therefore the pair is produced within the line cycle time of 3 seconds.

The machine is fitted with dual stations and the main handling tasks are carried out by pneumatic actuators.

In light of the various model types (length, number and type of components), to reduce the re-equipping time to a minimum, some of the table stations are dedicated to single models and do not require re-equipping. In light of the complexity of the some of the positions of the components, the line has an integrated robotic loading system.

LPG-Gasoline commutator device

Main features: rotary table with 8 dividers, semiautomatic, two pieces processed simultaneously, assembly, inspection and laser marking.

Rotary table machine with 8 stations and pneumatic power component movement. Loading carried out entirely by operator. Possibility to process diverse commutator models.

The line performs assembly and functional inspection using:
• Circuit programming equipment;
• “Light guide” inspection equipment;
Vision system for controlling LED functioning;
Final inspection equipment with function simulation and control of button engagement;
• Laser marking unit (in the case of specific logo and data matrix).

Saving of all production and testing data, as well as incoming Work Orders, through the interface with the external SQL server to guarantee total traceability of each single piece and remote management.