A new test station, which was built by Barr & paatz,will automatically produce and leak-test 75,000 screenwash containers annually and is currently demonstrating a 99 per cent success rate.

Barr & Paatz designed the workcell using advanced 3D solid modelling software. It then fabricated the automated assembly and test station in-house, using a Mitsubishi controller and operator display panel, Fumess Control leak detector, Sauven Codamark marking device, Sick safety light grid, Bosch Rexroth extruded aluminium framework and customer free-issue parts.

The cell was supplied and commissioned within 18 weeks and is now producing single- and twin-pump containers for the latest Land Rover.

As a major subcontractor to the automotive industry, Kautex Textron produces a clear vision systems (CVS) range that coves vehcle screenwash and headlamp cleansing systems, including injection-moulded water tanks,telescopic jets and hose assemblies. The company’s extensive experience of plastics processing enables the production of cost- and space-efficient parts, which meet special requirements such as fluid and air tightness, heat resistance and stability. This allows it to build a list of clients that includes Aston Martin,Audi,Bentley, BMW,Nissan,Toyota and Volvo as well as Land Rover.

Hengoed is the group’s twenty-eighth plant to be established worldwide, and manufactures CVS equipment for the UK and European automotive sector. All system components are injection-moulded and assembled on usly, water containers were assembled and leak-tested manually in order to meet the part quality standards demanded. Having decided to automate this small, yet critical process, Kautex Textron CVS invited design and price tenders from three companies, including Barr & Paatz, which had earlier built a machine for another application.

The testing process

In this latest application, two injection-moulded halvs of the Land Rover headlamp and screenwash water container are hot plate welded together before an operator loads each unit into the assembly an test station. The machine pre-tests each container and, if it is acceptable, fits various components to the moulding, carries out functional testing, and finally leak checks the whole assembly and codes it with an approved ink mark. Any rejected items are dropped through an aperture in the machine’s baseplate into a lockable bin.

The machine is controlled by a Mitsubishi MELSEC, which is linked directly to a Mitsubishi E600 HMI, for simple touchscreen practice the containers come in two variants-one with a single pump for screenwash and the other with two pumps for screen and headlamp wash. As appropriate, the pump or pumps are manually loaded into component nests, where they are retained by vacuum cups, only activated on use as an energy-saving operator then loads a float switch, which is again held by vacuum and once the operator is clear, the working area is again held by vacuum , and once the operator is clear,the working area is guarded by a Sick LGT satety light grid system, for protection of fingers, hands and personnel.

Fully automated

Operating in fully automated mode, the machine makes the electrical connections, inserts the pump/s into the container and seals the pump ports,before insetring the float switch and wiring. It then runs the pump/s, measures the working current and rotates the float switch 120 degrees to check proper switch , the container is sealed and pressure is applied via a WEH quick coupling connection to the neck. It is then checked for leaks with a Furness Control FCO730 detector; if the rate of decay is within acceptable limits, the completed assembly is marked by a Sauven Codamark reciprocating ink printer and released for operator removal.

The workcell’s structural framework is made from Bosch Rexroth modular aluminium extrusion, with stainless steel infills below the container fixture and clear polycarbonate panels above, providing a protective barrier system; reject assemblies are collected in a lockable bin within the to load and unload the machine is through the safety light grid, which has a response time of <50 milliseconds, and the assembly process is triggered by means of an Allen Bradley Zero-Force touch button, ergonomically designed to prevent repetitive interface disorders.

参考译文：

一种由巴尔&帕茨新生产的检测设备，每年能够自动产生75000个挡风玻璃清洗（screenwash）容器，并一一进行泄漏测试试验，目前其成功率在99%。

巴尔&帕茨利用先进的三维实体造型软件设计了功能模型。随后在试验室内制作了自动化装配机构和测试站，使用了三菱（Mitsubishi）控制器和指令显示面板，Furness控制检漏仪，Sauven codamark 标识装置，Sick安全光栅，波许（Bosch Rexroth）挤压铝框架和客户免费发行部分。

这套设备委托在18个星期完成，而且正在为最新上市的车型路虎产生单，双泵容器。

作为汽车行业的知名零部件生产商，考泰斯（Kautex Textron）公司努力为汽车驾驶者提供一个清晰的视觉系统（CVS），产品范围涵盖汽车挡风玻璃清洗（screenwash）和前照灯清洗系统，包括注射模压水箱，伸缩式软管总成。该公司广泛的塑料加工经验，使其有能力生产出低成本和高空间利用率的零部件，以满足特殊的要求，如流体和气密性，耐热性和稳定性。这使得它赢得了很多的合作伙伴，其中包括阿斯顿马丁，奥迪，宾利，宝马，日产，丰田和沃尔沃以及路虎。

Hengoed是该集团在世界范围内的第28个工厂，这里将为英国和欧洲的汽车公司制造清晰视觉系统（CVS）设备。所有系统部件均注射模塑成型和现场装配。此前，水箱都是人工的组装和进行泄漏测试试验，以满足零部件质量标准的要求。在考泰斯（Kautex Textron）决定将这个小而关键的过程自动化之后，其CVS部门进行了招标，权衡了三家公司的设计能力和价格竞争力，其中包括巴尔&帕茨，它早些时候已经制造了一台有其他应用的机器。

测试过程

最新的应用实例是，路虎前照灯两个半块注射模塑块的和挡风玻璃清洗液容器焊接在一起，之后将各个模块安装到测试台上。该机器首先分别对每个容器预测试；如果合格，就将各个部件装入模具，进行功能测试，最终对整个系统进行泄漏检查及盖上“合格”的印章。任何不合格的产品都将通过机器底板的孔被投入到一个可开闭的箱子中。

该机器的控制核心是三菱的melsec，结合三菱e600人机界面，支持触摸屏操作。实际上，这些模块可以分成两组——一组具有单泵用于挡风玻璃清洗，另一组有两个泵，分别给挡风玻璃和前照灯清洗。在某时刻，泵被手动加载，各个功能模块的真空可以保持，出于节能考虑只有使用时激活。操作器执行一个靠真空控制的浮动开关，一旦操作器空着了，工作区将由Sick LGT安全光栅系统保护起来，以保证手指，手等人身安全。

全自动模式时，机器自动通电，将泵插入容器和密封泵接头，然后安装浮动开关和配线。然后运行泵，测量工作电流，并旋转浮动开关120度，以确保开关位于正确操作位置。接下来，容器被密封，并能过WEH快速耦合连接到颈部。然后，用弗内斯fco730控制探测器检查泄漏；如果压强衰减率在可接受的限度内，该系统将被标记上Sauven chdamark的印章，可以正常使用了。

该自动控制设备的框架是由博世力士乐（Bosch Rexroth）铝型材挤压而成，容器下面由不锈钢填实，容器上面有聚碳酸酯板，提供了一层保护机构；不合格产品会被收集在框架内部的一个可开闭的箱子中。启动和关闭机器是通过安全光栅，它的响应时间不超过50毫秒，装配过程是通过Allen Bradley的无触摸按钮触发，很人性化的设计防止了重复界面操作可能带来的混乱。