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Thanks to the impetus of Industry 4.0, automated solutions have now permeated various production and assembly stages across multiple industries. However, in certain scenarios, manual assembly remains a more economical and practical choice. Yet, facing the high-intensity and continuous assembly rhythm, manual workstations are prone to issues such as delayed actions, incorrect screw picking, and repeated tightening due to operator fatigue. These issues can lead to an increase in product defect rates, significantly affecting production cycle times and efficiency. Eliminating these "negative actions" is crucial to ensuring the stable and efficient operation of manual assembly stations.

Pain Point 1: Screw Picking Confusion

Manual workstations, being open spaces, often have casual screw picking processes. Especially when the quantity of screws is not well controlled, there is a high risk of missing or dropping screws, leading to assembly defects. Moreover, due to human visual limitations, it is difficult to accurately distinguish between screws with minimal length differences, increasing the risk of mixing screws during the picking process.

Solution: A drum counting screw feeder can be customized to set the number of screws to be picked, supplying a fixed quantity of screws to employees. Equipped with a color display screen, it allows intuitive parameter adjustment and fault information viewing. Structurally, it can be designed with both OK and NG material boxes to achieve length detection and sorting functions, automatically screening out NG screws. Additionally, it can be paired with a barcode scanning function to prevent mixing of screws during manual replenishment. The straight vibration track drive uses a more stable electromagnet, reducing the likelihood of screw jams and ensuring smoother screw conveyance.

Pain Point 2: Frequent Process Errors

Manual workstations involve multiple assembly processes. Due to the repetitive and continuous nature of the tasks, operators are prone to fatigue, which can lead to errors such as missed or repeated tightening. These errors increase the rate of non-conforming products and reduce production efficiency due to rework operations.

Solution: By using a positioning lever, the tightening positions can be preset, ensuring sequential tightening. The XYZ direction positions are detected, and the tightening action is only executed when the program's set position is recognized. The tool can only be moved after the tightening is completed to proceed to the next set position, thereby avoiding errors such as repeated tightening and missed tightening. Additionally, the lever can reduce the weight of the tool and absorb the torque reaction force, improving the comfort of manual tightening, reducing operator fatigue, and increasing productivity. Smart guidance software can also be used to guide workers through standardized and orderly tightening operations, achieving control of tightening program switching and precise control of tool start and stop based on positioning, preventing errors and omissions, and reducing assembly defects.

Pain Point 3: Inconsistent Tightening Quality

In manual workstations for new energy motor and power control products, the tightening process is complex, and the requirements for final tightening quality are stringent. However, due to product interference conditions and material factors, manual operations can easily result in inconsistent screw tightening outcomes.

Solution: An integrated blow-and-suck module can handle various complex interference conditions. After the operator moves to the tightening position, simply pressing the start trigger can effectively control the automatic screw feeding and tightening. Combined with a lever and intelligent tightening tools, this solution can manage the number of tightenings, tightening sequence, and tightening quality during the production process. It also reduces operator fatigue, further improving the quality and consistency of tightening.