We designed and built a fully automated robotic line for final product assembly, from PCBAs to packaged, ready-for-sale products.
The line consists of six robots, with specific roles. PCBAs are supplied by the SMT department in panel form, already inspected via AOI.
An automatic cutting station separates the single PCBAs, which are then conveyed to the first robot station.
The line is designed to be flexible and reconfigurable in order to assemble different product models.
Pick-and-place robots are guided by advanced vision systems that, based on the kind of product being processed, identify in real time where to place each component.
Information is collected, associated with the board Data Matrix and saved in the company systems throughout all phases, including electrical and functional test results, programming data, visual inspection photos and process parameters.
This allows complete and certifiable product traceability, useful both for quality control and after-sales support.
The first robot pre-assembles some plastic components while the second robot picks up the board and reads the unique datamatrix on the PCB.
Then, the PCBA is programmed, tested with dedicated tools and validated before mechanical assembly.
The robots handle product assembly, including screwing operations with torque control, joints and mechanical fastening operations.
The line also allows customised laser engraving on the final products, with data such as the serial number, DataMatrix/QR codes, company logos, compliance marks or other graphics requested by the customer.
Before being packaged, the product passes through an automated visual inspection station that takes multiple shots from different angles. The images are analysed by an artificial intelligence vision system to detect cosmetic flaws, scratches, misalignments, assembly errors or missing parts.
Only compliant products go on to the next stage.
The final station consists of an automatic boxing machine, which folds and forms the box, places the user manual and the validated product inside it, and closes the package. All without any manual intervention.
