More ergonomics, faster processes and lower costs – that is the result of process optimization Turck at the Halver location for the manual assembly of electronic circuit boards. Instead of using one Royonic table as before, the employees now assemble the circuit boards on two tables Pick-to-light workstations. The new solution was planned and implemented sensors from the Turck subsidiary Mechatec in close cooperation with production planners from Halver.

Contents

• SMT or THT PCB assembly?
  • Royonic tables in the THT configuration
• Press the operating button for 240 hours
  • Practical experience in work preparation
  • Ergonomic workplace design

SMT or THT PCB assembly?

When assembling circuit boards, manufacturers rely on this in most applications SMDtechnology (Surface-mounting Technology), as this process works fully automatically. As soon as wired electronic components are to be installed, alternatives like this are available THTprocess (Through Hole Technology) is required. The components are inserted through contact holes in the circuit board, which still requires manual assembly work today. To do this, employees place the individual electronic components on the circuit boards, which are then soldered using a soldering wave and thereby firmly connected to the circuit board's conductor track.

Royonic tables in the THT configuration

Depending on the size of a circuit board and the number of components to be assembled, this can Assembly process very complex become. For process and quality assurance, so-called Royonic tables are often used in the THT assembly of circuit boards. This was also done in the THT assembly at Werner Turck GmbH in Halver. The Royonic table uses a light pointer to show the employee the location on the circuit board where the respective component needs to be fitted. As a rule, there are 8 to 15 similar circuit boards in a transport frame. Each time a component is inserted, the employee presses a confirmation button on the table.

Press the operating button for 240 hours

Within the framework of the lived CIP process At Turck, production processes are also regularly checked. In the case of THT assembly with Royonic tables, the work preparation came to the conclusion that this type of assembly requires cost and process optimization.

The process experts in Halver calculated that employees alone 240 hours a year spend pressing the confirmation button. What was also not efficient was that the employees had to manually lift the frames with the circuit boards onto a conveyor belt to the soldering wave. Overall, there is a lot of potential to increase the efficiency of THT assembly.

Control cabinets | News, tips, transport

For Alexander Kohlhaas, an expert in manufacturing technology in Halver, was clear that the Royonic tables are not optimal for circuit boards with up to 15 components. Initial ideas led to the choice of a pick-to-light solution with system components from our own company. In addition, the frame transport should be automated. This relieves the employees of having to carry the frames and optimizes production. The process runs more smoothly, and the logistics processes such as filling components should no longer interrupt the assembly process, but should be carried out by the logistics employees.

Ergonomic workplace design

Kohlhaas developed in collaboration with Natalie Krumme, then a mechatronics engineer trainee, came up with the idea for a THT workstation based on a pick-to-light system. After the production planners had defined the functionality and ergonomics requirements of the application, a subsidiary came on board:

Turck Mechatec offers complete electrical system solutions according to customer specifications from planning to turnkey handover. The Mechatec specialists developed a system solution based on the requirements profile and implemented it in an ergonomic and cost-optimized manner.

With his Pick to lightTurck has already equipped numerous customers' manual assembly and picking stations with solutions. Mechatec was therefore able to draw on the automation specialist's extensive wealth of experience when planning its system and combine the optimal individual components with software developed specifically for the THT application in Halver.

The software not only controls the process, but can also record the productivity of the THT assembly and visualize it on a separate monitor. By collecting data, further starting points for optimization can be identified in a later analysis.

On the hardware side, there are two new assembly locations HMI / PLC systems used, a BL67 I/O station as well as various sensors and illuminated buttons including connecting cables. Today, the employees stand in front of two ergonomically designed pick-to-light shelving systems that can be equipped with up to 48 compartments for components to be installed.

Efficient assembly process with HMI

An assembly process begins with inserting the empty circuit boards into the frame support. The individual ones are displayed on the large HMI/PLC screens Work steps presented visually and the next component to be assembled is displayed with the location and assembly position on the board. The display on the monitor also serves as work instructions. This eliminates the need for training times and makes the deployment options for production employees more flexible. Parallel to the display on the monitor, an activated light signals the shelf space from which the employee must remove the component that is currently being installed.

After the employee has assembled the component on the circuit board, she activates this process by touching the capacitive pick-to-light sensor and the visualization on the monitor shows the next assembly position. At the shelf locations, the pick-to-light sensor lights up with the component to be removed next.

Once the circuit boards are complete, the employee pushes the frame onto the conveyor belt. The frames with the assembled circuit boards are automatically transported via the conveyor belts to the soldering wave and then back to the workstations. There, the employees remove the fully assembled and soldered circuit boards and fill the frame again with empty circuit boards for the next round.

The Shelves are designed in such a way that they can be filled with new components from behind without interrupting the assembly process. The producing employee is thus released from logistics tasks and can concentrate on her actual assembly task. The two shelves are also a step forward from an ergonomic point of view. Instead of lifting the component frame, which weighs around 8 kg, off the assembly line for assembly, a conveyor belt now carries the frames with the circuit boards to the employees. All you have to do is push the frame briefly until it is caught by the conveyor belt and transported to the soldering wave.

Practical experience in work preparation

All the necessary preparatory work for the assembly of new products can be carried out Work preparation now carried out externally. With the help of a CSV file, the entire process is described and the procedure is defined. In addition, the production planners can determine whether the workplace is used by one employee or two employees in order to shorten the throughput time of the products.

As soon as the new product is started, all you have to do is save the CSV file including images IPC and the BL67 station can be loaded. In the future, the solution can also be connected to the new merchandise management system without much effort.

Initial experience shows that the assembly process optimized with Pick-to-Light at full capacity brings about a significant increase in production at workplaces. Today the soldering wave is continuously and evenly utilized. Interruptions in the process, which previously occurred when refilling components, have been largely eliminated.

This also made it possible to reduce the error rate, as interruptions in the assembly process are always sources of error. The bottom line is that the investment in the optimized system will quickly pay for itself.

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