Water Filter Assembly System

Background: 

Hilton Engineering joined forces with Aylesbury Automation Ltd to look at the potential for a ‘‘next generation’’ assembly machine that would eradicate previous production inefficiencies experienced with the assembly operation for components from this UK company's water filter range.

The Problem: 

The most pressing problem that needed to be addressed was the insecurity of two of the filter components; the material filter strip and the plastic filter lid. The time and distance between attaching the components and ultra-sonically welding the components together posed a risk to the assembled product. The inertia from the process at times caused the components to become detached and misalign, resulting in high levels of rejection at the final assembly stage of the process.

Separation of components consequently had a negative effect on the whole assembly system, creating a 2-3% component failure rate and slowing the overall production process.

The Solution : 

Aylesbury Automation’s dedicated sales, design and engineering teams respond to their customer’s problems by providing specific and effective solutions, drawing on over 40 years of experience and design expertise. 

Aylesbury Automation’s team focused their skills and knowledge on designing and constructing an automatic rotary indexing machine that secured and welded the components at the same station, eliminating any risk of component detachment. 

Enhancements to UV light technology combined with a built-in camera made detailed quality checks possible, and an additional set of grippers were added to reduce discrepancies in tape tension that had previously resulted in unusable filter material components. 

Benefits: 

Careful consideration of this company's previous assembly problems opened the door to providing an assembly system that could maximise production potential; Aylesbury Automation’s AA6 automatic rotary indexing machine now provides the customer with a cost-effective, reliable and durable investment that has substantially increased assembly production, reduced reject rates and significantly improved the overall process. 

Aylesbury Automation has a long and distinguished history in supplying Special Purpose Machines to international manufacturing companies. The business is active across a broad industrial spectrum including food, electronics, automotive, packaging, cosmetics and pharmaceuticals, the proprietary self pierce riveting system and a complete range of parts handling, feeding and automation products and systems. 

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