Robotic Capacitor Processing Line
A fully automated production line developed for Vishay Dimona to replace a manual three-operator process. The system integrates Nitric, Sol, Updraft drying, Dust processing, automated tray handling, database-driven recipes, and robotic unloading.
Customer
Vishay
Year
2022
Project Duration
8 Month's
Industry
Electronic Components Manufacturing
Solution Type
Automated assembly lines, Robotic Automation Systems
Scope
• Turnkey project
, • Manufacturing
, • Assembly
, • PLC and HMI programming
, • Database integration
, • On-site installation and commissioning
Technologies
KUKA Industrial Robot, Cartesian XY Gantry Systems, Siemens PLC, HMI, Database Integration, Barcode Identification, Automated Tray Handling, Chain Conveyor, Controlled Dipping Systems, Temperature Control, Process Monitoring, Dust Handling, Recipe-Based Process Control
Location
Dimona, Israel
Project Status
Completed and operational
Project Specifications
Customer
Vishay
Location
Dimona, Israel
Year
2022
Duration
8 Month's
Project Status
Completed and operational
Industry
Electronic Components Manufacturing
Solution Type
Automated assembly lines, Robotic Automation Systems
Scope
• Turnkey project
, • Manufacturing
, • Assembly
, • PLC and HMI programming
, • Database integration
, • On-site installation and commissioning
Technologies
KUKA Industrial Robot, Cartesian XY Gantry Systems, Siemens PLC, HMI, Database Integration, Barcode Identification, Automated Tray Handling, Chain Conveyor, Controlled Dipping Systems, Temperature Control, Process Monitoring, Dust Handling, Recipe-Based Process Control
Automated Capacitor Processing Line
PILCO developed the NSD system for Vishay Dimona to automate a production process previously operated manually by three workers. The machine processes capacitor trays through Nitric, Sol, Updraft drying, and Dust stations according to product-specific recipes retrieved from Vishay's database. Two XY gantry systems handle trays through the liquid-processing stages and into the oven, while a KUKA KR 10 R1440-2 robot transfers trays from the oven to the Dust station and unloading area. Depending on the capacitor type, trays can automatically skip selected process stations.
Challanges
- Sol Material Stability: The Sol material is thixotropic and sensitive to excessive mixing. Controlled circulation and mixing are required to reduce gelification risk while maintaining the required process characteristics.
- Uniform Oven Temperature: The Updraft oven must maintain the required temperature range across the complete tray area, with uniformity monitored at five measurement points.
- Dust Level Control: The Dust station requires stable and controlled powder level throughout production to maintain repeatable processing conditions.
- Flexible Product Recipes: Different capacitor types require different process sequences and parameters, and some products must bypass selected stations automatically.
- Multi-Technology Integration: The machine combines liquid processing, blotting, drying, Dust processing, gantry handling, robotics, conveyors, PLC control, HMI, barcode identification, and database communication in one automated line.
Solutions
- Two XY gantry systems for automated tray handling through the Nitric, Sol, and oven-loading stages.
- Controlled Nitric and Sol dipping stations with adjustable process parameters.
- Dedicated blotting stations following the relevant liquid processes.
- Controlled Sol circulation and mixing designed to reduce gelification risk.
- Chain-conveyor Updraft oven with monitored temperature profile and five-point verification.
- KUKA KR 10 R1440-2 robot for tray transfer between the oven, Dust station, and unloading stations.
- Automated Dust dipping, Dust level monitoring, and programmable tray shaking.
- Siemens PLC-based machine control and custom HMI programming by PILCO.
Results
- Replacement of a manual three-operator process with a fully automated production line.
- Automated tray processing based on product-specific recipes retrieved from Vishay's database.
- Automatic station bypass according to capacitor type.
- Improved process repeatability across Nitric, Sol, drying, and Dust stages.
- Reduced dependence on manual process decisions and operator handling.
- Integration of mechanical systems, robotics, controls, and production data into one automated line.
- Designed for cycle times of approximately 40-90 seconds per tray depending on product type.
Challanges
- Sol Material Stability: The Sol material is thixotropic and sensitive to excessive mixing. Controlled circulation and mixing are required to reduce gelification risk while maintaining the required process characteristics.
- Uniform Oven Temperature: The Updraft oven must maintain the required temperature range across the complete tray area, with uniformity monitored at five measurement points.
- Dust Level Control: The Dust station requires stable and controlled powder level throughout production to maintain repeatable processing conditions.
- Flexible Product Recipes: Different capacitor types require different process sequences and parameters, and some products must bypass selected stations automatically.
- Multi-Technology Integration: The machine combines liquid processing, blotting, drying, Dust processing, gantry handling, robotics, conveyors, PLC control, HMI, barcode identification, and database communication in one automated line.
Solutions
- Two XY gantry systems for automated tray handling through the Nitric, Sol, and oven-loading stages.
- Controlled Nitric and Sol dipping stations with adjustable process parameters.
- Dedicated blotting stations following the relevant liquid processes.
- Controlled Sol circulation and mixing designed to reduce gelification risk.
- Chain-conveyor Updraft oven with monitored temperature profile and five-point verification.
- KUKA KR 10 R1440-2 robot for tray transfer between the oven, Dust station, and unloading stations.
- Automated Dust dipping, Dust level monitoring, and programmable tray shaking.
- Siemens PLC-based machine control and custom HMI programming by PILCO.
Results
- Replacement of a manual three-operator process with a fully automated production line.
- Automated tray processing based on product-specific recipes retrieved from Vishay's database.
- Automatic station bypass according to capacitor type.
- Improved process repeatability across Nitric, Sol, drying, and Dust stages.
- Reduced dependence on manual process decisions and operator handling.
- Integration of mechanical systems, robotics, controls, and production data into one automated line.
- Designed for cycle times of approximately 40-90 seconds per tray depending on product type.
Turnkey Solutions Built for Precision & Performance
Mechanical Design
Complete mechanical design of the automated NSD production line.
Custom Machine Engineering
Purpose-built system integrating Nitric, Sol, Updraft, Dust, and automated tray handling.
Robotics & Motion Integration
Robotics & Motion Integration
PLC & HMI Programming
Siemens PLC programming and custom HMI development by PILCO.
Database & Recipe Integration
Automatic product identification, database communication, and recipe-based process control.
Manufacturing & Commissioning
Manufacturing, assembly, on-site installation, SAT, commissioning, and post-installation support.
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