Design and manufacture of a system to semi-automatically perform a leak test of an automotive air-conditioning system, whilst being assembled on a moving production line. The system is pneumatically based and controlled via a PLC. The operator engages the test head with the Climate Control Unit Under Test and initiates the test sequence by pressing a start button integrated with the handle. The test head then seals itself on the Unit Under Test and the leak test starts as the system is driven down the production line (at production line speed) by a 2.5m rodless cylinder. At the end of the test, the test head automatically disengages and returns back up the production line, ready for the next Climate Control Unit to be tested.

Quadratec has developed a Die-Casting Machine Process Monitoring System based on National Instruments ‘Labview’ software, to enable the key process parameters (pressure, velocity and temperature) to be monitored. This ensures acceptable process control, producing SPC data as required. The system consists of a non-contact ram displacement transducer, ram pressure transducer and thermocouples. The data is acquired by a PC data acquisition system at 1kHz and various displays and curves of up to 25 key parameters produced for each shot.

Design and manufacture of an automated, two stage, press feed system for window hinge components, to increase production rate from 13 parts per minute (manually) to 90 parts per minute for the automated system. It was based on a 35 tonne press and caters for 8 different sizes of component. The system comprises a marshalling table, a two stage walking beam with guiding pneumatic cylinders to control component loading and unloading, a mis-feed detector, component oiler and material discharge via a small conveyor.

Automated Press Feed Datasheet

Design of a robotic Welding Jig to produce a 2.25m x 2m x 0.5m structure. This is fabricated from 20 separate assemblies, individually clamped and positioned by the jig to within 0.5mm. Clamping was achieved using 31 clamping positions, of which 22 were pneumatic for auto-clamping and release. The jig was then mounted to a 360°, 2 tonne indexer and two ABB robots used for the welding operation.

Welding Jig Datasheet

Design and manufacture of an automated jig to allow flame spraying of two different car instrument panel (IP)/dashboards. The design of the jig necessitated two different support geometries, one for each IP, along with different masking requirements. The jig had to accommodate both left hand and right hand drive models, so requiring identification of four different parts. This was achieved by the use of a logic system based on four optical sensors. Correct positioning of the part in the jig was required to approximately 0.5mm. This was achieved by edge detection using two narrow beam laser sensors. Operation of the masking system was via a pneumatic cylinder controlled by a PLC, when the sensors indicated that the appropriate IP was in place.