Switches being conveyed through the assembly system

660 Switch Assembly System

challenge

A JR customer needed a machine to assemble flip switches. JR designed and built the 660 Switch Assembly System, which assembles and tests residential and mobile home light switches at a rate of 45 parts per minute.

solution

The 660 Switch Assembly System is divided into four main zones:

Terminal Assembly
AMI
Precision Link Conveyor
Ground Strap Assembly

The assembly equipment consists of five major sub-assembly cells, each functioning to accomplish “milestone” stages of the 660 switch assembly. Each up-stream cell operates at a slightly faster rate than the adjoining downstream assembly cell to prevent starving the downstream cell. The five sub-assembly cells are:

AMI rotary dial assembly machine – Assembles the body, push springs, bumpers, and toggle spring
Dorner accumulating conveyor – Accumulates parts going to the next cell
Terminal rotary dial – Assembles screws to terminals, stakes the end of the screw to prevent backing out
Dorner loop conveyor – Places terminal assemblies onto pucks that travel on a conveyor, delivering them to the AMI cell for insertion into the body
Camco precision link indexer – Completes the remaining component assembly and testing before offloading for packaging

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outcomes and benefits

• Cycle rate of 45 parts per minute

Light Switches Roll Off This Efficient Assembly System

Industry

Consumer Products

Technical Capabilities

Assembly Solutions Inspection & Testing

Region

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