Written by An Automotive Project Leveraging Industry 4.0: Tork Mekatronik’s Innovative Solutions
Project Overview At Tork Mekatronik, we successfully implemented an advanced automotive project for a client, leveraging Industry 4.0 principles. The project features a pre-assembly station, an injection machine, and a test-packaging line to ensure high quality and efficiency.
Assembly and Testing Process In the pre-assembly station, we perform tests such as resistance, conductivity, servo axis pressure, and part parallelism before and after assembly. This prevents irreversible damage during injection. Faulty parts are sorted into a red box, controlled by sensors to halt operations if errors are not addressed.
Injection Process During the injection process, all parameters are meticulously controlled and logged into a Microsoft SQL Server. Deviations from reference values are detected, and faulty parts are segregated. Each injection cycle’s parameters and results are documented for traceability and quality assurance.
Testing and Packaging Process Our fully automated testing line cools the parts, conducts air leakage testing with an ATEQ F620 device, measures resistance and conductivity, performs laser marking, and visual inspections. Successfully tested parts are automatically sorted into designated bins, while faulty parts are directed to a locked red box. All test results are recorded in the SQL Server, allowing remote monitoring through our custom software.
Dummy Parts To ensure the testing line’s safety, operators must run pre-prepared dummy parts at the start of each shift. The system requires dummy parts within 20 cycles to resume operation, bypassed only with a special code known only to authorized personnel. Even if authorized personnel continue the operation with the code, the line stops again after 20 parts, making continuous production impossible. Dummy parts are detected by color sensors, ensuring the system’s integrity.
Results Our testing line has performed approximately 5 million cycles with over 99% availability and operates at a defect rate of 0 PPM (zero parts per million), which indicates the rate of defective products sent to the customer.
Future Goals Future goals include using test data to optimize injection machine parameters, embracing machine learning for continuous improvement and design enhancements.
This project exemplifies our commitment to quality and innovation, leveraging Industry 4.0 to provide our clients with reliable and efficient solutions. At Tork Mekatronik, we strive to push the boundaries of technology, ensuring top-tier performance in every project.