The Need:
An automatic assembly line for assembling cups with lids for the beverage industry.

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Pre-Development Manufacturing Process:

Manual assembly of the assembly, multiple production workers, low productivity, high defective product rate, difficulty in attaching a valid barcode sticker, and challenges in the quality inspection process, as well as injuries and punctures during the needle assembly process.

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The Solution:

Development of an automatic assembly machine based on an automated station carousel.

Description of the Process:

• Various product components are concentrated into the carousel using feeders, vibrators, and other means, arriving at the feeding point with the appropriate orientation.

• At each station, a specific process is performed, starting from part feeding, component assembly, quality checks, and ending with the unloading of finished products.

• The machine is fed with the upper cover, and a mechanism is used to screw the needle (intended for functional testing) with the required torque.

• Subsequently, the airtightness of the needle mechanism is checked under air pressure to ensure compliance with the standard.

• In the following stations, the cup is fed, and then the cover is sealed onto the cup at the designated station with the required torque.

• If the LINE-ON tests at the inspection stations do not confirm the product's quality (leakage or failure to reach the required torque), it is diverted to a container for defective products.

• If it passes the quality checks, a validation sticker with an expiration date is attached, and it is subsequently released into a box of valid products.

• High-level control and remote monitoring are implemented.

• (Note: The translation may not be exact, as the provided description contains some technical terms that may have specific meanings in the context of your industry.)