Web-based Assembly Machine

Scope

Web handling machine with one main substrate feed and 9 narrow web cross feeds. Machine punched and placed up to 8 different pad materials onto PSA. Twelve different families were possible. All die sets and cross fed materials were interchangeable. Precision guiding and indexing of the main web were required. This web handling machine included vision inspection, online laser barcode marking & verification, and an on-demand quality control sampling station. Punch & die technology included custom self-guided dual-punch sets, custom cam-driven punch gantry system and automatic electronic die life tracking. Web handling technology included dancer-controlled unwind and rewind, custom mechanical chucks to meet customers narrow web specifications, slitting, removing release liner, and re-applying a protective poly coating to protect the product.

Client automation need

Customer desired to be first to market. Finished product from the McClellan assembly system had to meet or exceed calibration samples made in the laboratory.

Customer entered into a parallel development with McClellan: development and refinement of the product occurred by the customer while the assembly system was being designed and built. This forced weekly video teleconferences and updates to ensure both paths arrived at the desired result. McClellan's automation engineering staff aided the customers scientists and product managers in defining the physical construction and form of the products so that automatic assembly could be achievable.

Technological Challenges:

Servo indexing a "stretchy" web to within +/- .001".
Prevention of punch adhesive build-up.
Inventing a punch method that a) fits in the tolerance boundary for component placement, b) was robust and not prone to damage after several million cycles, and c) allowed for sharp cut edges despite material residue build-up.

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McClellan's web handling system capabilities

McClellan's machine vision system capabilities