case study

Waterjet Box: Footrest Cutting, Gluing and Clip Assembly

The scope of delivery is an automatic assembly of car mat clips during the carpet production process. The carpet is manually loaded and then cut by a robotic application. In the last step, the clips are applicated. Then the product is manually unloaded.

Overall description

Clip topology

    • clips method (pressing or rotation)
    • fixing of mate in the carpet (with or without external support)
    • the assembly hole in the carpet needed or not

Degree of automation

    • manually and semiautomatic (loading of parts manually, clip assy automatic)
  1. Carpet molding
  2. Foaming (opposite part of clip overfoamed)
  3. Waterjet cutting
  4. Footrest gluing & clips assembly

  • integrated assembly solution (forming or cutting tool, subassembly in foaming tool, subassembly in waterjet fixture)

  •  
  • position check
  • nondestructive check of clamping force
  • comparative check of process forces
  •  

Layout Design

Process Flow

Station 1:

Loading of foamed carpet 2 pcs. (manually)

Loading of 8 pcs. clips upper part (manually)

Loading of footrest (manually)

Station 2:

WJ cutting peripherie&holes (robotic)

Glue application on footrest (robotic)

Footrest assembly (robotic)

Station 3:

Clips application (robotic)

Part unloading (manually)

Process Flow

Station 1:
Loading of foamed carpet 2 pcs. (manually)
Loading of 8 pcs. clips upper part (manually)
Loading of footrest (manually)

Station 2:
WJ cutting peripherie&holes (robotic)
Glue application on footrest (robotic)
Footrest assembly (robotic)

Station 3:
Clips application (robotic)
Part unloading (manually)

Process Flow

Station 1:
Loading of foamed carpet 2 pcs. (manually) – Loading of 8 pcs. clips upper part (manually) – Loading of footrest (manually)

Station 2:
WJ cutting peripherie&holes (robotic) – Glue application on footrest (robotic) – Footrest assembly (robotic)

Station 3:
Clips application (robotic) – Part unloading (manually)