Automation of a wiring assembly line with 12 workstations
Project name:
Wiring assembly line
Location:
Sibiu, Romania
Date:
July 9, 2021
Project Type:
Assembly
Intro:
We developed a complete automation solution for a wiring assembly and processing line, designed to manage the production flow and work processes across 12 assembly workstations.
The line consists of 12 workstations, arranged six on each side, separated by a central conveyor equipped with wooden plates on which the cables being processed are fixed.
The flow is fully automated — each cable is identified at the entry point by scanning a barcode, which automatically loads the program and recipe corresponding to the type of cable being processed.
Process Overview:
Based on the barcode, the system determines which workstations need to be activated for that cable type (e.g., 1-3-4-5-7-10 for one model, or 1-2-4-5-6-10-12 for another).
At both ends of the line, automatic lifts transfer the plates between levels, enabling a continuous circular flow: the cables move through the line, are processed, and then return to the initial position for the next cycle.
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Automation and Control:
The entire system is controlled by an industrial PLC, with an intuitive HMI interface displaying in real time:
- the active recipe type,
- the estimated execution time,
- performance comparison between cycles (whether a batch was completed faster or slower than average).
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Operators can edit, add, or delete recipes directly from the HMI, providing full flexibility in production management.
Our Team’s Contribution:
The project was entirely carried out by our team, covering:
- design of electrical schematics and the automation panel,
- programming of the PLC, HMI, and frequency converters,
- implementation of control logic and recipes,
- installation and connection of sensors and equipment on site,
- proposing and implementing functional optimizations for the workflow.
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The mechanical part of the line was developed in partnership with a specialized conveyor construction team, ensuring perfect integration between mechanics and automation.
Benefits:
- Full traceability through barcodes;
- Intelligent automation with automatic recipe selection;
- Visual and analytical performance control;
- Quick configuration for different wiring models;
- Continuous and efficient flow between workstations.
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Location
Strada Constantin Moise Nr.11