June 12, 2017

Inflator Assembly Line

Machine No. 6322

Inflator Assembly Line

The operator manually loads dual tube inflator cups into a nest on a 16 position indexed dial plate. A barcode label on the inflator is read and the serial number is validated with the supervisory production data tracking system. The empty inflator is weighed to determine the tare weight of the part. Dual pellet feeders load pre-weighed portions of pellets into each tube. After each portion is loaded the weight is checked and reported to the data tracking system. Filled inflator cups are automatically transferred to a nest on a 2nd 16 position indexed dial plate where manually loaded and conveyor fed pouched cups are tested for weight and good pouched cups are placed into the inflator tubes. Reject pouched cups are offloaded by a chute into a reject part bin. A vibratory bowl feeds caps into a dual track where they are placed 2 up into the inflator cup tubes and the tubes are crimped. Good assemblies are offloaded into a chute and manually transferred to a station where a new serial number label is printed and applied. After labeling, completed assemblies are manually placed on a scale where they are again weighed and the final serial number barcode is read and reported with the weight value to the data tracking system. Reject inflator cup assemblies are offloaded by a chute into a reject part bin.

MACHINE CONTROL – A solid state programmable controller operates the sequence with an easily accessible control panel including Main Power, Emergency Stop, Start, Reset, Immediate Stop pushbuttons. Touch screen panels at each operator station provide all other human-machine interface functions

CYCLE RATE – 7 parts/minute

CONSTRUCTION – Heavy duty welded and powder coated tubular frame with adjustable levelers. Materials and finishes used are appropriate for the work environment. This machine is designed to allow the operator full visual contact with all components being processed and easy access for routine maintenance.

SAFETY – Meets OSHA Safety Standards. Safety sensitive areas of this machine are enclosed and accessed through interlocked doors which stop the machine when opened. Emergency Stop Controls are provided which stop the machine when activated.

Machine No. 6411

Single Stage Inflator Assembly Line

This assembly cell, of semi-automatic operator loaded machines, produces a range of single stage air bag inflators. The assembly cell is arranged in a “U” shape and single part flow is maintained through the process. A supervisory control and traceability system coordinates the cells and collects important assembly and test data. The system starts by applying an in process bar code label to the upper housing and then resistance welding an orientation pin to the housing. The next operations press an ignitor retainer into the upper housing, and laser welds it in place. An ignitor is then loaded and crimped in into the retainer, and a shorting clip is installed. At this point, an enhancer charge is dispensed by weight and loaded into the retainer and is closed up by crimping a sealing disk in place. The next operation presses a wire mesh filter into the upper housing, which is then filled by weight with a gas. The filter cavity is then sealed by pressing a sealing disk into the filter. The next operation applies a burst seal to the inside of the lower housing, and then the upper and lower housings are brought together and friction welded. The upper/lower housing sub-assembly is then pressed into a flange and the flange is subsequently laser welded in place. The orientation pin is also broken off at this point in the process. The fully assembled inflator is then leak tested, electrical tests are performed, and the finished units are labeled and packed out.

Controls – Each machine in the line is controlled by an Allen-Bradley Control Logix PLC. The operator interface is provided by an Allen Bradley Pannel View at each machine. Supervisory control and data logging are provided by a customized ManIT system that is connected to all of the PLC’s in the line.

Cycle Rate – A complete assembly leaves the line every 17 seconds.