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Insight's Process Solutions
Assembly ● Testing ● Gauging ● Inspection

- Engineered to Excellence

Putting parts together (assembly), is seemingly easy. But assembling 'correctly', requires in-depth process engineering, be it-
- calculating pressing loads at different combinations of shaft & hub tolerances
- or say the right torque for screw fitment
- or may be the way auto loading of a bearing, an O-ring or a screw is done onto a part for further fitment
- or appropriate tolerances on locating pins or bushes, etc., and/or so forth.

Do the process engineering well & you've built a sustainable assembly line, else it is a series of never ending problems, corrections, tweaks & what not!
A fine assembly line 'just works', and works reliably. And that's how Insight's crew of Process Automation experts build these systems. Indeed, a well engineered Process line, greatly minimizes or well in fact eliminates stoppages / breakdowns and as a result shoots up OEE.

Bush Pressing Machine, Torquing Machine, Assembly Fitment

Robust build quality, performance oriented design and meticulously engineered elements, typify Insight's Processing Machines, be it Assembly Fitment, Leak Testing, Performance Testing, Auto-gauging, Vision Inspection and so forth.

Let's take a look at a few solutions:

Assembly Cell for Bearing Housing of Oil Pump

Here's an assembly cell built for a major European automotive major, installed in Italy.

Considering lower initial production volumes, end-user needed a simple assembly cell that just does the job.

The cell was carefully engineered and built with scalability and future automation in mind.

Reliable production calls for robust and meticulous machine design & build quality. Here's an example of a simple yet high reliable assembly cell.

End of Line | Performance Testing | Case Oil Pump of 4-Wheeler

Installed in multiples, at one of the global-leaders who has a wide foot-print in the arena of manufacturing across the industries viz., automotive, infrastructure, energy, aviation and many else (!), this EoL machine serves the purpose testing critical sub-assemblies made for one of the India's largest Car Manufacturers.

Multiple part variants with easy change-over of fixtures, ease of test program edit / change through HMI, high quality testing sensors and equipment, make up the nature of this set of machines.

Foundational Schema

Single or Multi-Station

Progressive or Simultaneous Assembly
Preceding Process Validation | Sensing

Linear or Rotary Indexing

Layout driven | Semi or Fully Automatic
Progressive Process Streamlining

Auto Part Transfer

Vibratory, Magazine, Vacuum Feeders
Palletized Conveyor | Pick & Place

Monitoring & Traceability

Process Monitoring | Part Traceability
Data Capture & Analytics | Reporting

Process Assurance

Process-specific parameter validation
Progressive process interlocks

End-of-Line Validation

Performance Testing | Inspection
Vision, Laser, Optical, LVDT, Analog

Repertoire

Press Fitment Machines

Composite sub-assemblies offer a whole lot of merits over making single large parts, be it aluminium or steel casings with hardened bushes, and then relative motion between parts requiring bearings is another example where fitting 2 parts together simplifies product design.
And hence, press-fitment is an integral part of any assembly shop-floor.

Insight's Press Fitment machines are typically featured with:
(i) Adjustable press-load feature
(ii) Load sensing & monitoring
(iii) Press depth sensing & monitoring
(iv) Data recording, analytics & traceability
(v) Visual process parameter graphs & monitoring intelligence
(vi) Auto centralised lubrication for all moving elements
(vii) Control system matrix with PLC + HMI, IIoT ready
(viii) Easy & powerful diagnostics through HMI
(ix) Optional auto loading / unloading Automation

Power source of press could be:
(i) Servo-press (ii) Hydraulic or Pneumatic (iii) Hydro-pneumatic

Press Fitting Machine, Press Fitment Machine, Bush Pressing, Bearing Pressing

Torquing Machines | Screw Fitment Machines

Gone are the days of an operator manually positioning the torquing gun and going about it. Process automation is the way to go - to remain competitive in the market.

As the manufacturing industry inches towards Smart Manufacturing - monitoring the process, capturing data & part traceability, are becoming mandatory requirements, necessitating an electrical architecture in the machines that supports this evolving paradigm of i4.0.

Assembly of 2 or more parts using fasteners i.e., Torquing the screws / bolts, is a simple operation. And quite ironically - building a simple machine is quite a complex affair!

Be it single position torquing or a multi-axes multi-position torquing, architecture much be simple, but robust. Simple nuances of outlook are crucial, such as high speed positioning for multi-position torquing is elementary to quicker takt times.

And where there's high speed, there's vibration, and hence the structural architecture becomes a make or break for a good machine.

Finally, the heart of any torquing machine - 'the wrench' is crucial in terms of features & capabilities that sort of plug in like a matrix that fits the purpose.

Torquing Machine, Screw Fitment Machine

Sealant Dispensing Machines | Glue | Grease | Oil

With the advancements in adhesion-technologies, many companies across the industries, are turning to adhesive-bonding as a mode of assembly operations.

Depositing metered adhesives is done through different techniques, be it manual applicators or automated dispensing with Robots & process automation systems. And such systems can be built for pretty much any type of adhesive - from low to high viscosities.

Operating parameters such as flow-rate, dispense-pressure, purging to ensure homogeneity, control of premature curing, and so forth - are to be carefully taken into systemic consideration to ensure that the dispensing process is precise, accurate & repeatable.

The core idea is to apply adequate amount of liquid adhesives or sealants onto a specific substrate – in a time controlled manner, in the correct trajectory and in the most efficient bead shape and size.

Very similar but a simplified bottom-line is true - for filling machines.

Sealant Dispensing Machine, Glue Dispensing, Oil Dispensing

Powder Dispensing | Augers | Handling

Multitude of new-age applications hover around management of powders. Whether various powders of different grit sizes used for battery manufacturing, food industry, feeders for powder metallurgy sinters, or the ones used for 3D printing.

Insight's nuanced understanding of this simple yet important technology, helps it's customers choose the right method of dispensing in a controlled manner. Volumetric control is the most critical of many other parameters - that defines the effectiveness and accuracy of an auger.

And then, it's not just about dispensing, it is about making sure that there are no or minimal / inconsequential air-traps - which necessitates a nice system that keeps the powder 'stirring' and lets the air escape.
Some applications require either minimizing or blocking off the exposure to atmosphere - which then needs a well designed flow-schema which is sealed well.

Heart of such a system is the profile of the auger-screw - which facilitates better flowability of the powder, carefully minding it's cohesive & adhesive properties.

Powder Auger, Powder Dispensing, Powder Handling

Online Measurement | Non contact | Laser | Optical

In high volume production scenarios, end-to-end production lines that integrate metrology in a real-time online mode - are the only way to have a sustainable production set-up that exudes competitiveness in terms of end-user's trust in the shop-floor or the supplier.

Insight's domain experts in Metrology & Measurement, specialize in helping it's customers choose the right method of online inspection systems which truly make human-dependence and wrong-part supply - inconsequential.

Be it laser systems, optical measurement, eddy current sensing, a well designed machine which minimizes detrimental effects such as vibrations or thermal effects - on the measured value, is critical to a reliable inspection set-up.

Both the structural matrix and control architecture of the system - exercise significant impact on the consistency of the machine.

A fine balance of these and a host of other engineering nuances - is a make or break in terms of machine-build.

Online Measurement Systems, Non contact measurement, Laser Measurement, Optical Measurement, Eddy Current Testing

Auto Gauging Machines | Simultaneous | Offline

Medium volume production where process-assurance & statistical control are well organized in some cases and not so in some, or the cases where there are significant number of measurement parameters in the part - which warrant a dedicated inspection system, are a couple of the scenarios where Auto Gauging truly benefits the production line.

The fact that it is 'Auto' - quite naturally implies such machines must not call for high degree of operator skill, in fact must facilitate no-skill operation at best.

Whether it is bore measurement through APGs, a simple position sensing through LVDTs, mere presence checks through proximities or more sophisticated vision/camera systems, or precision measurements such a surface roughness, profile inspection and so forth, there's a specific 'way' in which each of these techniques must be employed for reliable yet easy & consistent gauging.
And that 'way' is the method of actuation and motion-guidance on a case-basis.

And then, the Fixturing for the part to be gauged, is most often simple - yet requires care and fitness to purpose.

Auto-gauging, Offline Gauging, Gauging, Auto gauging machine

Leak Testing Machines | Dry Leak Test

Function critical assemblies such as a battery pack chamber, an engine block, oil pump casing, crank-case housing, gear-box housing, valve bodies, to name a few - must operate in a leak-free way or within the boundary conditions of certain leak characteristics. Quite simply, lesser the leak (or no leak at best), the better the performance gets.

Whilst there are many others leak testing techniques, it important to define first whether detection of the leak is important or the measurement of the leak-rate is. Quantifying leak-rate dictates the choice of measurement technique - be it pressure change, flow measurement or changes in concentration - all as a function of time.

During testing, how & where should the sealing be done - more crucially - 'the how', is something that calls for careful engineering of the sealing actuators & fixturing of the part.
Machine design-wise - sealing parameters such as force of sealing for a given leak-test pressure, exposed area, structural rigidity, part deformation limits, and a host of other aspects are critical to performance & seamless working of the machine.

Leak Testing Machine, Dry Air Leak Testing, Dry Leak Test

Performance Testing Machines | Endurance | Durability

Determining a product’s performance be it - durability, speed, scalability, handling, and stability, are critical to any product launch or even testing an existing product for revised operational characteristics.

Quite simply - intent of testing is to reveal faults & ensure that the product (a part or a sub-assembly) is fit for end-use. Identifying potential performance issues before production deployment can greatly avoid unnecessary delays & production costs. And the test results - as a key indicator of product quality, help manufacturers gain tangible acceptance from the end-users & customers.

When a machine does the testing of another mechanism or a part, it is critical to realize that the machine itself is a mechanism made up of many parts. Behaviour of machine elements must not influence the test results of actual part / product being tested. This is where experience & in-depth machine engineering become tremendously crucial.
Once the mechanical aspect is holistically taken care of, it is the controls, sensing, monitoring, recording and reporting - that translate the test results into meaningful reports. The controls and software architecture - are as important as the hardware itself.

Endurance Testing Machine | Durability Testing Machine | Function Test Rigs

Vision Inspection | Machine Vision

Machine Vision is fundamentally the use of industrial cameras, right lenses, and appropriate ambient lighting - to perform automated visual inspection of parts.

When done right, machine vision is a fast & reliable method of in-line part inspection. Pretty much every part coming out of a high-speed manufacturing or an assembly line - can be imaged and/or inspected - to ensure reliable quality control.

In a shop-floor, machine vision can automate validation / inspection of parameters like the appearance, defects, wrong assemblies, presence-absence check, part type verification, dimensional measurement, capturing codes such as barcode, QR code, 2D DTM, and so forth.

Whether is about quantity/count recording, foreign matter/defect detection, position verification or dimensional validation, selecting right 'eye' - the camera, is critical to reliable outcome.
And then, putting across the right mechanical architecture around the system - be it the actuators, correct lighting, vibration-free mounting, make up the design philosophy of vision systems.

Endurance Testing Machine | Durability Testing Machine | Function Test Rigs

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