Automated Test Station
An automated test station concept that brings leak testing and dimensional inspection of automotive components together in one station. Every part's test result is recorded against its serial number.
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Problem
Test steps were performed manually at different points, and results were written onto paper forms. Because different operators could read different results on the same part, traceability and customer audits were difficult.
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Engineering Approach
We redefined the test procedure step by step and made measurement uncertainty the starting criterion of the design. Fixture repeatability was addressed before any measuring instrument was chosen.
Robotic loading takes the operator's influence out of the test cycle. Non-conforming parts are physically separated, and results are written to a database together with the part serial number.
Project images
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Applied System
The system was structured so that its mechanical, electrical and automation layers were designed by one team. Main components:
System components
- Caged leak test island with robotic loading
- Test fixture with reference pins and pneumatic sealing heads
- Dimensional inspection step with a touch probe
- Flow and pressure measurement unit
- Reject chute for non-conforming (NOK) parts
- PLC + industrial PC, results database and labelling
