For its assembly line for CEE plug-in connections, Wilei awarded Weiss the complete workpiece carrier transport and handling contract. As a system provider, the Buchen-based company took over the associated linear assembly system and the linear motor axes for handling, which this time were not supplied as individual components but as a completely configured and pre-assembled overall system. Although CEE plug connections are a typical mass-produced product, they are known for their notorious diversity of variants. For connector assembly, this means the greatest possible flexibility with short cycle times or, in the specific case of Bals, 60,000 units per week in 300 variants - a real challenge for the Wilei special machine.

For reasons of space and expansion, a linear system was specified from the outset. With the LS 280, Weiss has a linear assembly system in its range that fulfills all requirements as a "cut-away rotary indexing table". To transport the workpiece carriers to the processing stations, the LS 280 relies on the proven cam drive perfected by Weiss with all its advantages: smooth motion sequence, high positioning accuracy without additional indexing steps and therefore short cycle times.

Linear motor axes are the heart of the system
In addition to the linear assembly system, Weiss was also able to offer the appropriate handling components and deliver the system completely pre-assembled and wired ready for installation. Weiss made an advance contribution and took over the design of the system even before the actual order was placed. The result is impressive: An LS 280 with 14 processing stations transports the workpiece carriers. After inserting the retaining plate, these pass through three processing stations where the individual connector pins or sleeves as well as the springs and contact openers of the quick-connect system are inserted. The necessary handling is performed by a combination of three freely programmable direct drives: a horizontally mounted HG-25 and a vertically mounted HL-50 linear motor axis as well as an ST-55 rotary module for rotating the gripper. All three handling groups run on a single, one-meter-long HN-100 linear motor axis to save space. To accommodate three axis combinations with free programmability of the X, Y and Z axes as well as a rotation axis in such a small space is only possible if you know the installed components "like the back of your hand".

Three Weiss axis combinations running on a single HN-100 linear motor axis to save space and supplied as a completely pre-assembled, ready-to-install system. (Image: Weiss)

Perfect division of labor on the machine
Once Weiss had ensured flexibility, precision and fast handling with a cycle time of just 8.5 seconds, the Wilei team was able to focus on the actual assembly process: After the assembly steps, the assembled connector passes through a test station for the pull-off forces and a completeness check. Special variants can be added at a manual workstation before the connector is completed at the screwdriving station and finally ejected. Wilei is satisfied with this division of labour in the construction of the system: Weiss supplied the know-how for handling and feeding, while Wilei, as a special machine manufacturer, brought together and harmonized all processes.

The Weiss Application Software, W.A.S. for short, made it easy to set up and program the handling units: W.A.S. takes over the complete control of the axes and the linear assembly system, the higher-level PLC only reports whether a part is in position. The changeover between the connector variants stored in the W.A.S. takes place automatically. Because the hardware, electronics and software come from a single source and are perfectly coordinated, the cycle times remain correspondingly short. Added to this is the convenient operation of the W.A.S., which, with its intuitive interface, requires no programming knowledge. pb