An American aerospace manufacturer approached RedViking to design a fully automated assembly solution for three different variants of jet engine bearings. The existing manual process was not only time-consuming but also posed safety risks to employees and was prone to human error. The goal was to develop a fully automated assembly cell for jet engine bearings that would Increase throughput and efficiency while also improving employee safety and product quality.
Key Benefits:
- Increased Throughput
- Enhanced Safety
- Higher Quality Assurance
- Reduction of Human Error
Automated Assembly Cell
RedViking designed a modular assembly cell capable of handling three different bearing variants. An incoming cart was manually loaded with individual components, which were placed in specific nests designed for each part. The cell could automatically identify which bearing variant was being assembled. Once the cart was loaded and checked by an operator, the robot would initiate the assembly process. The assembly included steps like heating, cooling, and pressing components together. An automated vision system and stand alone gage station checked the assembly against the aerospace manfuacturer standards, ensuring compliance with aerospace quality requirements.
After assembly, completed bearings were off-loaded onto a designated cart for quality assurance and further processing. The assembly time for the #2 bearing decreased from 6-8 hours to just 2 hours and 40 minutes, allowing for three bearings to be produced in the same time previously required for one. Similar reductions were achieved for the #5 and #6 bearings, demonstrating significant improvements in throughput.
This project represented the first step in the manufacturer’s broader initiative to automate their plant, setting the groundwork for future robotic integration. The successful collaboration between the aerospace manufacturer and RedViking led to a transformative automation solution that enhanced productivity, safety, and quality. By overcoming the challenges associated with transitioning from manual to robotic assembly, the manufacturer positioned itself for future advancements in automation within the aerospace industry.