TCU (Transmission Control Unit) Assembly
One of the first steps during the TCU assembly is mounting four speed sensors and one vehicle connector in Throu-Hole-Technology on a PCB.
The process is guided an monitored by a camera system in order to compensate tolerances in the components. Additionally the inserting force and the position in relation to the PCB gets monitored.
Originally, the PCB handling was planned and designed so that it could be carried out by workers. Optionally, an interface to other machines in the assembly line is implemented to enable the customer to automate handling to the wave soldering machine.
Of course, the machine sends all serial numbers of the components handled in one assembly cycle, to the costumer's MES system.
Final Assembly & EOL Test
In the first Station of the final assembly machine a worker places one upper and one lower housing in the fixtures.
A robot then handles a fully assembled PCB from the SMD line into the upper housing.
In the third station the lower housing gets applied to the pre assembled unit.
Sensors check that all tabs are engaged before another robot handles the unit to the test stations.
After the unit went through the flash stations and the RF tests, an optical inspection system checks if the pin positions of the electrical connectors are in tolerance.
Finally, the unit is labeled before being forwarded to either the scrap parts stacker or the outgoing conveyor.