ULR Robotic Assembly and Finishing Station
The ULR is a versatile and fully automated production machine. In its basic configuration, the ULR station is used for fully automated, robotic finishing of induction coils, performing a range of operations (assembly, electrical connections, tinning, parameter measurement, and insulating tape wrapping).
Above all, the ULR is a modular technology platform. When designing this machine, we created a design and programming base that can be freely rebuilt, expanded, and adapted to the specifics of your unique product and production process. This device is an excellent case study of our engineering expertise, demonstrating how advanced, multi-stage technological processes can be integrated into a single, compact, and efficient unit.
➤ Precise Loading and Positioning: Components are picked from pallets or an intelligent infeed conveyor. Internal transport is handled by a fast and extremely accurate Yamaha SCARA robot. The robot head is equipped with an integrated servo-stepper motor that rotates the gripper 180° and a pneumatic gripper with a system of interchangeable jaws.
➤ High-Temperature Fluxing and Tinning: Automatic flux application using a narrow overflow nozzle powered by a digital, precision diaphragm metering pump. The coil leads are then precisely dip-tinned in a crucible. The station features an automatic mechanism for oxide removal and dross collection.
➤ Automatic Electrical Testing (QC): The component is inserted into a removable measuring socket, where pneumatic actuators press the measuring couplings with dedicated electrical contacts. The station works closely with an electrical tester that checks the product's parameters.
➤ Mechanical calibration (terminal assembly): Precise, controlled insertion of tinned, protruding pins into the coil body using dedicated pins and pneumatic clamps.
➤ Insulation and taping (wrapping): Automatic wrapping of the winding with insulating tape using the number of wraps specified in the program. The station is equipped with a tape gripper, a guide with adjustable height and width, a pressure roller, and a cutting knife.
➤ Sorting and unloading: Compliant products are transferred to the return conveyor. Products that fail the electrical test are automatically dropped by a robot into a designated safety zone for non-compliant products.
➤ High-performance and precise production with minimal operator intervention: The basic premise of the ULR machine was to minimize human intervention in the production process.
➤ High efficiency is ensured by the use of precision components and stations, the placement of sensors at key machine locations, buffers and product pallets, and an automatic control station. This makes product production more repeatable, reliable, and hands-free. Employees only need to periodically reload the buffer with new products or retrieve a completed batch of products.
➤ The machine can also be integrated into a production line by adapting conveyor belts, trolleys, or pallet transporters (between the previous and next stations) or by installing a packaging cell. This further reduces human intervention and increases productivity!
➤ Rapid changeover (SMED): The machine was designed with production flexibility in mind. Switching to a different product type requires only loading the program from the HMI panel and simple, tool-free or quick-tool replacement of dedicated equipment (e.g., robot gripper arms, measuring cell, pins, or bumpers).
➤ Advanced control with an intuitive interface: The heart of the system is an Omron PLC industrial controller connected to a modern HMI operator panel. It enables direct programming of robot movements (in PTP and Linear modes), editing of technological parameters (e.g., immersion speed and depth, delay times, strapping settings), and full input/output diagnostics and event viewing.
➤ Compact and mobile "Plug & Play" design: The entire station is enclosed in a rigid, welded frame with a footprint of just 1.2 x 1.2 m. The lower section of the frame is designed to enable seamless and safe transport of the entire machine by forklift to another location within the production hall.
➤ Top-class safety: The station fully meets the essential requirements of the machinery directives (CE certification). It features an advanced safety controller (Safety PLC), dual-channel emergency stop monitoring (E-STOP), and movable guards equipped with safety interlocks with a controlled opening delay (the interlock releases only after the hazardous movements have stopped).
Thanks to its modular mechanical design, proprietary control architecture, and the precision of the integrated SCARA robot, the ULR station can be customized and adapted to the production of your products in a variety of industries!
➤ New applications in the automotive industry:
➤ Production of sensors and sensors (e.g., position, ABS, temperature sensors). Replacing the soldering pot with a dispensing head for one- or two-component adhesives and sealing resins. The robot precisely applies sealant to the sensor housing. Snap-in assembly with force and travel control, leak and resistance testing.
➤ Production of solenoid valve coils for hydraulic systems, replacing the taping station with a resistance or ultrasonic welding station.
➤ Applications in the medical device industry: Assembly and precise wrapping of catheters, tubing, and medical tubing. Conversion of a coil taping station into a station for precise, spiral wrapping of medical microtubes with specialized protective tapes or coatings.
➤ Production of industrial, aerospace, dual-use, and consumer electronics components: Production of pulse transformers, micro-relays, and mains filters. The tinning station is equipped with a precise, selective mini-wave crucible. The winding taping station is adapted for applying Kapton insulating foils. Functional testing (FCT) (electrical tester coupled with test needles), marking of compliant products, and sorting.
➤ E-Mobility and Renewable Energy Sources (RES) Industry: Finishing and insulation of high-power chokes for inverters and battery modules. Conversion of robot grippers and workstations to accommodate larger component sizes. The taping station is adapted to wrap coils with thermally conductive or insulating tapes with high breakdown resistance.
ULR Machine Photo Gallery:
Technical parameters of the ULR machine:
| Parameter | ULR |
|---|---|
| Dimensions (L × W × H) [m] | 1,2 x 1,2 x 2,1 |
| Gross weight | approx. 650 kg |
| Main control | Omron PLC Industrial Controller |
| Robotic arm | Yamaha YK400XG150 SCARA Robot |
| Power supply | 3/N/PE AC 230 V / 50 Hz |
| Maximum power usage | 4,5 kVA (4500 VA) |
| Pneumatic power supply | Compressed Air 0.6 MPa |
| Noise Level | < 70 dB |
ULR is designed with interchangeable production sockets in mind
The ULR platform is designed with a nested approach. As a manufacturer of custom machines, we consider it a proven technological platform. This means that by choosing to partner with us, you have the opportunity to fully customize the machine to your expectations and process requirements.
| Workstation (Zone) | Role in the ULR | Possible alternative machining and finishing stations |
|---|---|---|
| Loading and internal transport station | Picks parts from pallets or an infeed conveyor with positioning strips. A SCARA robot with a 180° rotating head moves the part between stations and deposits the finished product. | • Vibratory feeder instead of a conveyor belt. • Tool change on the robot for a dedicated gripper or suction cup. |
| Dosing station | Applies flux to pins using a narrow overflow nozzle, fed by a precise, digital diaphragm pump with adjustable dosage. | • Precise dosing and application of potting/bonding compounds, adhesives, and sealants: one- or two-component adhesives, epoxy resins, or silicone sealants. • Precise spraying of protective coatings or varnishes using a spray nozzle. |
| Soldering station | Soldering and tinning of leads in a crucible with a liquid solder alloy, equipped with an automatic scoop and oxide removal mechanism | • Selective mini-wave soldering • Thermocompression, Hot welding and riveting, hot stacking • Spot/local hardening: Using high temperature to locally heat and harden small metal components. |
| Measurement and Quality Control Station | Mechanical measuring couplings activated by actuators press electrical contacts against the product placed in a replaceable socket. Measurement of the product's electrical parameters. The test result from the external tester controls sorting of OK/NOK (compliant/non-compliant) products. | • Visual quality control: Integration of inspection cameras to check geometric dimensions, correct assembly and orientation of components, or code readability. • Leak tests for valves, medical tubing, and electronics housings. • Press-fit tests: Measurement of the force and range of press-fit connections. |
| Mechanical assembly stations | Assembly, bending, or insertion of components into the coil body (or any other product) using pneumatic actuators, pressing pins, and shaping elements. | |
| Taping and wrapping station | Automatic wrapping of the product with insulating tape using using a system of rotating spindles, a gripper, a pressure roller, and a cutting knife. | • Product Labeling • Applying protective and shielding tapes: Applying specialized copper (EMI) or thermally conductive tapes to electronic components. |
Polish Production. European Engineering. Smarter Investment.
Choosing machines from NEOTECH means combining high-quality European engineering with a more competitive cost structure. For manufacturers operating in high-cost markets, this creates a clear business advantage: advanced automation, shorter payback periods and a stronger return on investment – without compromising on quality, reliability or technical performance.
We design and build custom production machinery and automation systems around your specific process, with one team responsible from concept and engineering through manufacturing, installation and commissioning. The result is not simply a machine, but a cost-effective, dependable production solution designed to improve productivity, reduce operating costs and support long-term competitiveness. With NEOTECH, you get the engineering capabilities and standards you expect from a European technology partner, combined with the cost efficiency that makes your investment work harder!
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