Unison has helped a global automotive supplier create in-house capability for the production of right-first-time components. The company in question is responsible for manufacturing boot hinge assemblies for several major automotive manufacturers.

The main component in these assemblies is a bent rectangular steel tube which was previously fabricated and supplied by a subcontractor. To reduce its reliance on outsourcing and ensure total control over accuracy, Unison’s customer decided to invest in an automated manufacturing cell to bring the production of boot lid hinge components entirely in-house.

Unison’s solution involved two all-electric, servomotor-controlled 50 mm Breeze tube bending machines with multi-stack tooling heads. The bending machines are fed by two automatic hopper loaders which perform weld seam detection and datum the tube prior to bending. A robot then unloads the bent parts from each machine and presents them to a four-camera vision inspection system, to measure the parts and calculate corrections.

This closed-loop solution links with the bending machine’s motion control to ensure accuracy and repeatability. Bent components are then transferred by a further two robots into two CNC machining centres, where multiple holes of various sizes are drilled. Once complete, the components are robotically deburred and hung on transfer racks in pairs ready for delivery to the assembly station.

In a high-demand industry, working to ‘just-in-time’ supply principles, the company now has the ability to reliably produce hinge components in-house, with complete control of all aspects of boot lid assemblies. Outcomes include improved quality control with repeatability and tight tolerances, easy tooling changeover and programming to produce different variants, reduced costs, and higher productivity.

More information www.unisonltd.com