Casing for distance sensors in four models made of PBT/GF30


Cycle time:
14 sec.
Tool construction:
5,25 mill.

(3 shift operation, 250 working days/year, 85% availability)

Brief description

The fully automatic circulating carrier transport system is used to produce casings for automotive distance sensors in 4 different models (for various end customers). Contact groups are bent in a bending/punching process by a flat, pre-punched punching bar, separated and equipped into a carrier. A transportation system carries the fitted carrier into a sorting station in which the contact group linking bars are undone so that the 3 individual contacts are positioned in a moulding set for the moulding. A subsequent testing device checks that fitting is complete and in the right location, that the contact linking bars are undone and controls the carrier temperature. The single contacts are then overmoulded in the injection moulding station. After overmoulding the sensor casings are demoulded, the cast-on section separated and the injection moulded parts are forwarded to an automatic inspection station.
The accuracy of the mould contour is ensured here and the individual contacts in the casing undergo an electrical resistance and high voltage test. Acceptable parts are then laser marked with a data matrix code. Before final orderly placement of the acceptable parts in deep draw trays, the legibility and completeness of the laser marking is checked using intelligent sensors. A palette changer for deep drawn trays enables system autonomy of approx. 4 hours' operation.