{"id":6474,"date":"2026-08-27T09:28:19","date_gmt":"2026-08-27T07:28:19","guid":{"rendered":"https:\/\/neotech.pl\/maszyny\/en\/?page_id=6474"},"modified":"2026-08-27T09:53:55","modified_gmt":"2026-08-27T07:53:55","slug":"ulr-automatic-production-cell","status":"publish","type":"page","link":"https:\/\/neotech.pl\/maszyny\/en\/automated-production-machines\/ulr-automatic-production-cell\/","title":{"rendered":"ULR – Automatic Production Cell"},"content":{"rendered":"\t\t
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ULR Robotic Assembly and Finishing Station<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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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).<\/span><\/p>

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.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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\n \n\t\t\t\t\t\t\t\t\t\t<\/i> <\/div>\n <\/div>\n\n \n 1. Description of the technology and capabilities of the ULR platform<\/span>\n\n \n <\/a>\n <\/div>\n\n
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\u27a4 Precise Loading and Positioning:<\/strong> 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\u00b0 and a pneumatic gripper with a system of interchangeable jaws.<\/span><\/p>

\u27a4 High-Temperature Fluxing and Tinning:<\/strong> 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.<\/span><\/p>

\u27a4 Automatic Electrical Testing (QC):<\/strong> 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.<\/span><\/p>

\u27a4 Mechanical calibration (terminal assembly):<\/strong> Precise, controlled insertion of tinned, protruding pins into the coil body using dedicated pins and pneumatic clamps.<\/span><\/p>

\u27a4 Insulation and taping (wrapping):<\/strong> 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.<\/span><\/p>

\u27a4 Sorting and unloading:<\/strong> 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.<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n \n

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\u27a4 High-performance and precise production with minimal operator intervention:<\/strong> The basic premise of the ULR machine was to minimize human intervention in the production process.<\/span><\/p>

\u00a0 \u00a0 \u00a0 \u00a0 \u27a4 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.<\/span><\/p>

\u00a0 \u00a0 \u00a0 \u00a0 \u27a4 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!<\/span><\/p>

\u27a4 Rapid changeover (SMED):<\/strong> 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).<\/span><\/p>

\u27a4 Advanced control with an intuitive interface:<\/strong> 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.<\/span><\/p>

\u27a4 Compact and mobile \"Plug & Play\" design:<\/strong> 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.<\/span><\/p>

\u27a4 Top-class safety:<\/strong> 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).<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n \n

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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!<\/span><\/p>

\u27a4\u00a0 \u00a0 \u00a0New applications in the automotive industry:<\/span><\/strong><\/p>

\u00a0 \u00a0 \u00a0 \u00a0 \u27a4\u00a0 \u00a0 \u00a0Production 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.<\/span><\/p>

\u00a0 \u00a0 \u00a0 \u00a0 \u27a4\u00a0 \u00a0 \u00a0Production of solenoid valve coils for hydraulic systems, replacing the taping station with a resistance or ultrasonic welding station.<\/span><\/p>

\u27a4\u00a0 \u00a0 \u00a0Applications in the medical device industry:<\/strong> 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.<\/span><\/p>

\u27a4\u00a0 \u00a0 \u00a0Production of industrial, aerospace, dual-use, and consumer electronics components:<\/strong> 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.<\/span><\/p>

\u27a4\u00a0 \u00a0 \u00a0E-Mobility and Renewable Energy Sources (RES) Industry:<\/strong> 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.<\/span><\/p> <\/div>\n\n <\/div>\n\n <\/div>\n\n