Automated 2-Part Assembly Pressing Simulator

Simulation Controls

Single Cycle Continuous

Simulation Speed 1.0x

Station labels Material flow Show parallel rotary fixtures

Failure Scenario Simulation

Selected fault repeats until cleared. If the same station fails 3 times, the HMI alarm stops the machine and highlights the station.

CONCEPT A Manual Pre-Sorted Linear Feeder Steady-state rotary-table process: all occupied fixtures work in parallel during each dwell. Station 1 loads Part A, Station 2 loads Part B, Station 3 checks assembly seating, Station 4 performs servo pressing, Station 5 performs block test, and Station 6 unloads OK/NG. After the dwell, the rotary table indexes clockwise one station pitch: S1 → S2 → S3 → S4 → S5 → S6.

Live Dashboard

Machine Status Idle

Current StepReady

Cycle TimeApprox. 7s

Theoretical Rate~514 pph

Production Count0

OK Count0

NG Count0

Station HMI / 3-Failure Stop

READY

S1 Part A Load0 / 3 fail

S2 Part B Load0 / 3 fail

S3 Assembly Check0 / 3 fail

S4 Servo Press0 / 3 fail

S5 Block Test0 / 3 fail

S6 Unload0 / 3 fail

Live Process Data / Logging

Active ScenarioNone

Press Load Cell0 kgf

Press Stroke0.0 mm

Block-Test Reaction Force0 g

Block-Test Displacement0.00 mm

Last DecisionReady

Pressing Graphs

Force vs Time

Force vs Displacement

Block-Test Graphs

Force vs Time

Force vs Displacement

Process Status

Feeder ReadyOFF

Part A PresentOFF

Part B PresentOFF

Press HomeON

Pressing CompleteOFF

Block TestREADY

Unload GateOK

Event Log

Concept Comparison

The simulator compares two generic feeder approaches for the same rotary-table two-part assembly pressing sequence.

Lower-cost concept

Concept A — Rotary Table + Manual Pre-Sorted Feeder

Operator pre-sorts Part A and Part B into linear / P-loop feeders.
Pneumatic pick-and-place loads Part A at Station 1 and Part B at Station 2.
Same fixture remains on the rotary table through check, pressing, block test and unload.

Higher automation feeding

Concept B — Rotary Table + Vibratory Bowl Feeder

Operator bulk-loads components into vibratory bowl feeders.
Bowl tracks orient and buffer parts before escapement and transfer.
Reduces manual sorting but keeps the same rotary table processing stations.

Cycle Time Basis

For a rotary-table design, the production cycle is governed by the longest active station plus index and settling time. It is not calculated by adding all stations sequentially.

Station	Operation During Parallel Dwell	Check / Data
S1	Load Part A into fixture	Seating / bottom position confirmation
S2	Load Part B into same fixture	Insertion depth / presence confirmation
S3	Assembly seating check	Top-down probe or sensor confirmation
S4	Servo pressing	Approx. 600 kgf press load + stroke profile
S5	Bottom block test	Approx. 200 g push-force response + displacement
S6	Unload OK / NG	OK route or reject route confirmation
Index	Rotary table indexes one station pitch	Example shown: 360° / 6 stations = 60° per station-pitch index

Planning Value

Concept AApprox. 7 sec/part

Concept BApprox. 7 sec/part

Cycle-time values are engineering planning values based on the simulated process sequence and must be validated with actual parts, tooling, feeder behavior and acceptance criteria.

Scope, Assumptions & Open Engineering Items

The simulator visualizes a generic concept. Final station quantity, fixture design and acceptance limits should be finalized after sample testing and process validation.

Common Process Scope

Part A and Part B loading into indexed rotary-table fixtures.
Assembly seating check before pressing.
Servo pressing with load-cell and stroke logging.
Bottom block test with force and displacement logging.
OK accumulator and reject bin / reject chute.
HMI station alarm, station fault count and repeated-failure stop logic.

Station Count Position

The shown six-station layout is a simulator reference. If more operations, longer process dwell, extra inspection or different feeding behavior is confirmed during testing, station count and index angle can be revised.

Validation Items

Part A drop-in / seating reliability.
Part B insertion repeatability.
Press force and stroke profile under actual tooling.
Block-test push force and displacement acceptance window.
Feeder singulation and buffer stability.

Logging / Failure Logic

Every station decision is recorded. The demo can simulate failure at each station. When the same station fails three times, the machine stops and highlights the station for recovery.

Station	Logged Data	Failure Response
S1	Part A presence and seating depth	Reject / stop depending failure count
S2	Part B presence and insertion depth	Reject / stop depending failure count
S3	Assembly seating check signal	Reject / stop depending failure count
S4	Press force vs time, force vs displacement and stroke	Alarm if load-cell / stroke profile does not match process window
S5	Block-test reaction force and displacement	Reject if force is low or displacement exceeds acceptance window
S6	OK / NG route confirmation	Alarm if unload or reject route is unavailable