Automatic Line for Assembly and Testing of Ball Valves

Fully Automatic Assembly
The FELP assembly system is engineered around three primary automated islands, each utilizing high-precision rotating tables to streamline the manufacturing process. The production flow begins with the pre-assembly of the valve body, followed by the sleeve pre-assembly stage to ensure structural integrity. These components then converge at the final assembly station, where the valve is completed with seamless synchronization, ensuring a consistent and rapid output that eliminates the variability of manual labor.

Integrated Audio and Leak Testing
To guarantee the highest standards of reliability, every valve undergoes a sophisticated "Burst" leak test that utilizes pressurized air injection combined with ultra-sensitive micro-leak detection. This process is further enhanced by integrated audio "pop" testing, which acoustically verifies the correct mechanical engagement of the components. Throughout this phase, the system maintains continuous quality control, utilizing an automated sorting mechanism that instantly separates and rejects any waste pieces to ensure only perfect units reach the end of the line.

Flexibility and Reconfigurability
This assembly system is designed for a versatile manufacturing environment where production needs can change rapidly. Operators can perform an electronic program change that triggers an automatic reconfiguration of the system, supported by programmable rotary tables equipped with absolute encoders for pinpoint accuracy. Furthermore, the system utilizes interchangeable holders that can be quickly swapped to accommodate valves of varying sizes, making it an ideal solution for facilities handling diverse product catalogs.

Advanced Operator Interface
The system is managed through two intuitive touch-screen panels that provide operators with total control over the production environment. These interfaces offer real-time diagnostics and detailed production statistics, allowing for data-driven decision-making on the fly. Managing complex production runs is simplified through a user-friendly interface that utilizes specific codes and visual images, ensuring that program management is accessible and straightforward.

Ready for Industry 4.0
Embracing the future of smart manufacturing, this assembly line comes equipped with a comprehensive hardware and software package designed for seamless integration with existing factory management systems. This connectivity allows for enhanced data transparency and process optimization. Additionally, the inclusion of a dedicated Virtual Private Network (VPN) Router enables secure remote assistance, allowing our technical experts to provide support and troubleshooting from anywhere in the world.

High-Performance Output
Engineered for high-volume manufacturing, this assembly system delivers exceptional throughput without compromising on precision. It achieves an impressive average cycle time of just 3 to 3.5 seconds per piece, depending on the specific valve configuration. When operating at a standard 90% efficiency rate, the line is capable of producing up to 1,200 finished pieces per hour, providing the industrial capacity required to meet demanding market schedules.

Robotic Automation
The core of this assembly system’s agility lies in its advanced robotic integration, featuring a combination of Selective Compliance Articulated Robot Arms (SCARA) and sophisticated Anthropomorphic Robots. These robotic elements work in tandem with high-speed pneumatic manipulators and brushless electric axes to perform complex movements with extreme repeatability. This blend of robotic precision and mechanical speed ensures that even the most delicate assembly tasks are handled with absolute consistency