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Automation reduces production time for LED lighting by 90%

Production-cost

By BizLED Bureau

Nov 28, 2016: Swiss manufacturer JESA saved about 90% production time for automotive LED lighting components. This was possible by a combination of injection overmolding, and robotic insert loading and part removal. This process replaced five manual assembly steps.

JESA of Villars-sur-Glâne specializes in custom-made ball-bearing solutions, like a dynamic adjustment mechanism for LED car headlamps. JESA produces these components for automotive LED lighting. It has replaced its traditional assemble process with US company ARBURG’s turnkey injection molding cell.

The automated cell helps to cut down production time to 10 sec— manual assembly process used to take 90 sec. This helped JESA to maintain a competitive edge in Switzerland. JESA has a facility in China as well.

The LED lighting actuators with integral ball bearings are manufactured in a cell based on an Arburg Allrounder 470 H hybrid press, and an Arburg Multilift V Cartesian robot. This system also comes with a palletizing station and a conveyor line, and a complex gripper.

The top-loading robot picks up four ball-bearing inserts per part at two loading positions, with the help of extended Z-axis (three at one position, one more at the other), using a pneumatic gripper. It places them in a four-cavity mold. Sixteen inserts gets held in the gripper.

The robot also demolds the finished parts and sets them down in a metal tray. Then the conveyor system channels the transport trolleys with the trays out of the system. Loading the inserts into trays and down- stream visual inspection and storage are the only manual operations.

Source: Arburg

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