Automated Cells for Pre-mounting of Components on Glass
dimaTEC is specialised in the design, manufacture and installation of automated cells for the pre-mounting of components on glass. It is a process aimed at specialist Tier 1 glass supply companies.
Depending on the degree of automation, we are usually dealing with either automatic machines, where the majority of the processes are carried out without the intervention of operatives (for example only the glass or brackets are loaded manually), or semi-automatic machines, where the operative performs a larger number of manual processes (for example the manual application of primer, the removal of liners, the gluing of brackets, etc.).
Automated Cells for Bracket Pre-mounting
In this case, the client required an automatic cell designed to perform the pre-mounting of 2 different types of bracket on the windscreen. The distinctive feature of the project was that the metallic rain-sensor brackets were fed horizontally on mechanised trays while the plastic camera brackets were fed vertically via foam trays.
The proposed design in this case centred on two gravity feeders, one for the brackets supplied vertically and the other for the brackets supplied horizontally. The operative in this case can load up to 3 full trays per feeder, meaning an autonomous bracket supply of over 3 hours.
The robot, in this case a Fanuc M-710iC/50, has a multi-tool that allows it to work with 2 different types of bracket, as well as a vision system capable of locating and referencing the brackets (without the need for mechanical centring), locate the glass screen-print, insert the bracket and subsequently measure, thanks to a vision system, the exact position of the insertion. This quality system is known as the Post Insertion Check (PIC).
The PU application equipment used is made up of a double pump and compact volumetric dosing unit with a PU quality control system by vision and an ultra-diffused light hood.
A large dimension oven was also installed to ensure the primer curing process. In this way it is guaranteed that the gluing of the brackets is done when the primer has correctly cured.
A centring station integrated into the transporter facilitates the positioning of the glass prior to the insertion of the bracket.
Finally, in the glass unloading zone, a free rotating table is integrated into the transporter so as to facilitate the pre-mounting of another component by the operative.
The robot picks up a bracket in the horizontal position with a principal tool and picks up the bracket in the vertical position using a lateral gripper. The robot moves the vertical piece and puts it on a centring table. Once there, the vision system, via the identification of unique references, is able to centre the bracket and send the correction coordinates to the robot (in three and a half dimensions) so that it can collect it with the main tool. Once the two brackets are correctly centred, the robot moves the pieces to the PU application zone and performs the application while the vision system controls the correct application of the PU.
In parallel, the glass loaded on the principal transporter is moved through the oven to complete the curing process, and lastly is deposited in the insertion zone. There, a mechanical centring system ensures the correct position of the glass.
Subsequently, the robot, using the built-in vision system, looks for the screen-print in the glass and performs the insertion/gluing of all the brackets. Once this operation is completed, it checks the correct insertion of each of the brackets via the Post Insertion Check (PIC). The glass continues its journey in the transporter until reaching the unloading zone. There, the operative, using a free rotating table system, carries out pre-mounting tasks (finisher gluing and rear-view mirror coupling).
Automated Cells for Bracket Pre-mounting
In this case, the client required a semi-automatic machine designed for the gluing of clips and spoilers on the windscreen. The distinctive feature of the project was that the operative had to load the clips manually and remove the liners as well as load the rear windows.
The proposed design in this case is based on a compact station where the operative loads the glass and applies the primer manually, loads the clips in the clip gluing device and removes the liner.
After this the operative removes and checks the glass. The table centres the glass and then the clip gluing device cylinders move down so as to allow the clip glue to come into contact with the rear window for a few seconds. Once the clips are released, the operative can remove the glass manually.
Cell for Metallic Security Plate Gluing
In this case, the client required a small cell designed for the gluing of the metallic security plate on the quarter windows. The distinctive feature of the project centred on the machine having to be able to do the left and right window in the same glass position, and both the feeding of the glass and the metallic plate had to be performed manually.
The proposed design in this case is based on a loading table with mobile centring limits (that adapt depending on the variant), metallic plate loading mould, KUKA Agilus robot, PU application equipment made up of a double pump and compact volumetric dosing unit with a PU quality control system by vision and an ultra-diffused light hood.
The operative loads the glass on the table and the metallic plate into the mould and validates. At this point, the robot moves to the position of the plate and picks it up. Then it moves to the PU dosing system. The PU application equipment used is made up of a double pump and compact volumetric dosing unit with a PU quality control system by vision and an ultra-diffused light hood.