ALPHR Technology Ltd is a UK based company specialising in the design and manufacture of bespoke production equipment.

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1 A U T O M A T E D E F F I C I E N C Y

2 ALPHR Technology Ltd is a UK based company specialising in the design and manufacture of bespoke production equipment. A full range of in-house facilities, from evaluation through to design, manufacture and commissioning, allows ALPHR to provide specific solutions to manufacturing organisations throughout the world. Driven by ambitious, experienced directors and supported by a strong and professional team, ALPHR is in tune with the needs of production managers and process engineers in today s demanding manufacturing environment. ALPHR offers a diverse range of equipment, from simple mechanical poka-yoke component sensing and orientation systems, through to fully automated assembly and test solutions incorporating sophisticated vision and advanced handling systems. This flexible approach allows ALPHR to provide equipment tailored to the individual requirements of each client. We originally obtained accreditation to ISO 9001:1994 in the year it was issued. Our successful transition to ISO 9001:2000 reaffirms our long-term commitment to providing the highest levels of quality. The combination of these factors allows ALPHR to lead the industry in providing bespoke equipment and customer service.

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4 Based in Letchworth UK, ALPHR Technology are a Special Purpose Machine Builder and Systems integrator offering many years of experience and knowledge in the field of automation. For over 26 years, we have been producing special purpose machines for some of the world s leading manufacturing companies including Intier, Nifco, UK-NSI, Continental, Ideal Boilers, Bosch, Visteon and Bespak, offering solutions to applications/ production issues across many industries. We at Ideal have been continually developing with ALPHR in delivering new production methods and techniques in order to deliver a flexible platform to produce a wide and varied product range. Throughout the last three years we have made a strong partnership and are happy to continue our working relationship, moving forward for the future. We believe at Ideal that with the help of ALPHR, we have increased our market share by being more adaptable to an ever increasing and demanding customer base. Our increased quality and reputation has been evident over the last few years since we launched our new products. I strongly believe that ALPHR will help us to keep ahead of the competion and make Ideal leaner and more efficient. Paul Turner- Manufacturing Engineer - Ideal Boilers We have formed a close working relationship with ALPHR Technology Ltd, who provide us with a wide range of automation solutions. They are responsive to our support needs and always produce a high standard of engineering. Richard Coutts- UK-NSI I consider ALPHR a partner. I m happy with the work that we have been able to develop together and I think this is having some visibility outside as well. Artur M.F. Graxinha- Test Core Engineer and Material Cost Reduction, Visteon Automotive Systems (Palmela, Portugal) On all occasions in dealing with ALPHR, they have managed to provide us with exactly what we were after equipment of excellent quality within very demanding time schedules. Matt Carmellotti- Manufacturing Systems Engineer, TRW Automotive

5 Over the years, manufacturing has not only changed in terms of technology, but also location with around 75% of our business now being truly worldwide. It is only by supplying machines of the highest quality and reliability that this can be achieved and with 95% of our customers purchasing multiple machines over many years, our dedication and commitment to our customers speaks for itself. Our extensive portfolio includes fully automated palletised production lines, rotary assembly machines, robot manufacturing cells, semi-automatic assembly and test stations to simple mechanical Poka- Yoke assembly stations. We specialise in both Industrial PC and PLC control systems, having experience with the leading manufactures such as Omron, Siemens and Mitsubishi. With over 40 employees, all design, assembly, wiring, tooling and development is carried out at our 12,000 sq ft Letchworth facility. To further complement our in-house facilities, ALPHR Technology work closely with suppliers such as Furness Controls, Omron, Cognex, Desoutter and Keyence to offer flexible solutions to production requirements. Our approach is to develop strong working relationships with all our customers with an emphasis on quality and practical automation. Our expanding customer base along with the long term relationships we have with all our valued customers is testimony to the quality, reliability and service we offer and pride ourselves in. Amor Way, Dunham s Lane, Letchworth Garden City, Herts SG6 1UG Tel +44 (0) Fax +44 (0) enquiries@alphrtechnology.co.uk 5

6 Electrical Testing ALPHR Technology has a wealth of experience in providing bespoke and innovative electrical testing solutions to meet the customer s requirements. A wide range of proprietary equipment can be integrated into an overall package. This can range from oscilloscopes, DMM s, RF generators, audio analysers to laser scribes and robotic handling systems. Over the years, ALPHR has used a wide range of industrial standard communication protocols such as: CAN LIN RS232 RS458 Ethernet Bluetooth USB These protocols have been used to communicate/interrogate a wide range of products including car radios, in-car entertainment systems, satellite navigation systems, ECU s, instrument clusters and even domestic boiler control boards. With a highly skilled and knowledgeable team, our in-house experience in the field of electrical testing has gained us an enviable reputation in the market.

7 Vibration Testing in the Production Environment PCB Function Testing Quality Laboratory Instrument clusters are subjected to vibration of random amplitude and frequency. The clusters are continuously monitored and current measurements taken to ensure no transient failures occur. Using a bespoke vibration fixture and controller developed by ALPHR, duration of test period, tests performed and associated limits are all user defined in simple menus. ALPHR Technology has developed a range of testers designed to verify the correct functionality of populated circuit boards before they are assembled into complete modules. These testers perform testing with the PCB operational, unlike in- Circuit testers which perform a lower level test of component presence and connectivity. All external analogue and digital inputs and outputs are tested. If LEDs are present they are checked for current draw, colour and intensity. The fixturisation developed allows test points to connect to the PCB enabling functions not available at the main connector to be tested. A range of testers has been developed to meet the requirements of QC laboratory testing which generally involves more detailed testing of the product than is performed on the production line but without the production constraints of cycle time and automated loading and unloading. A further range of testers is designed to perform the lifetime testing specified by most manufacturers. This generally involves controlling a number of products simultaneously and monitoring their basic functionality while they are subjected to days or even weeks inside environmental chambers which are being cycled through designated conditions. 7

8 In Car Entertainment Assembly & Testing Electrical Testing on Palletised/ Automated Assembly Systems Car radios are tested using an assembly of sophisticated equipment to provide suitable RF signal inputs and detailed analysis of the output signals destined to be fed to the vehicle loudspeakers. A large number of tests is generally performed to ensure the radio meets the design specification across all bands (AM,FM,DAB) in terms of frequency response, distortion and signal to noise ratios. Any auxiliary audio inputs such as USB, Bluetooth or SAT NAV alerts are also tested to ensure correct functionality. Any other functions integrated into the radio module such as GPS or satellite broadcast can also be tested using suitable equipment integrated into the tester. ALPHR Technology has considerable experience in electrical testing of a wide range of electronic based products, including control boxes, instrument clusters, PWM control valves, solenoid valves, rail network relays, in-car entertainment systems and satellite downlink modules. Electrical testing is predominantly carried out on PC control systems to allow data recording, communication to and from the modules, result interrogation and result algorithms to be created. Automated Electrical tests include: PWM signal control Current measurement Voltage measurement Frequency measurement Programmable DC voltage control Programmable AC voltage control Bi-directional communication with various products Resistance measurement Speed of switching in relays Drop in and drop out voltage/currents Hysteresis measurements and calculation

9 Instrument Cluster Assembly & Testing End Of Line Testing Vehicle instrument clusters are assembled in a range of machine configurations from simple assembly benches to automated rotary or palletised systems. The stations are designed to be user friendly with automated work instructions as well as a range of Poka Yoke checks. Correct assembly of parts is checked using barcode readers, vision systems and a range of suitable sensors. Once assembled the instrument clusters have the individual gauges (speedometer, tachometer etc) calibrated and validated using vision systems to ensure the indicated values are exactly as specified. Warning lamps are tested for colour and brightness as well as basic functionality. Automated calibration and full functional testing is performed on a range of automated electronic assemblies. Testers can be manually loaded or be integrated into palletised flow systems, there may be single or multiple test stations within one tester to achieve the required throughput. A range of specialised proprietary equipment is integrated into the tester as required. Full SPC results are recorded and these testers are often linked to factory CIM systems. LCD or TFT screens within the cluster are tested to varying degrees depending on customer requirements. Any other ancilliary functions performed integrated into the instrument cluster are tested. This may include visual warning systems, optical communications (MOST) and a range of analogue and digital features. 9

10 Automation A Technology driven company, ALPHR has used experience and knowledge of manufacturing and automation to help our many customer improve their production process. Whether supplying simple Poka Yoke assembly stations or fully automated production lines, we work closely with all our customers to understand their needs and requirements and propose practical solutions. Our many years of experience and knowledgeable team ensure that we always supply machines of the highest quality, designed and manufactured for years of trouble free operation. Robotics ALPHR Technology has used numerous robots in its history, including Cartesian, scara and full 6 axis, from many manufacturers. Applications include part Pick & Place, automated screwfeed systems, glue and sealant dispensing, robotic vision inspection/ part gauging and compression limiter placement and insertion. Many robots have been integrated into rotary assembly machines and palletised assembly lines as well as stand-alone robot assembly cells. The use of robots in automation can significantly reduce cycle time and operator input and therefore streamline a production cell. For Robotics & Leak Detection, see page 17

11 Rotary Assembly Palletised Assembly Cells Ultrasonic & Hot Plate Welding ALPHR Technology has gained considerable experience over the years in rotary assembly machines, including simple 2 station rotary systems up to more complex 8 station rotary machines. Rotary assembly machines allow for the minimum number of operators, generally for loading, whilst still allowing various assembly and test processes to continue in parallel. ALPHR Technology is one of the few companies who can confidently say that we specialise in palletised assembly lines. Automotive instrument clusters have, for many years, been assembled and tested on ALPHR Technology palletised systems, gaining us considerable knowledge and expertise in this field. We have been able to transfer this knowledge to many other products whose production is suited to this type of setup. ALPHR Technology has produced a large number of machines using ultrasonic welding as a standalone process or as part of an assembly line. Ultrasonic technology has been used for retaining, riveting or full hermetic seal welding of various products including instrument clusters, air ducts, automotive interior panels, circuit board retainers and a variety of injection moulded products. Many products, including plastic mouldings, automotive valves/solenoids, domestic boiler heat engines, engine manifolds, automotive instrument clusters and engine ECUs, have been manufactured and tested using rotary machines. Processes including leak testing, flow testing, vision inspection, current and voltage tests, insertion and insertion force tests, bowl feeding, sealant application, laser marking, engraving, communications and electrical testing. These have all been carried out on rotary machines, demonstrating the flexibility of this production method. Pallet systems allow for multiple production cells to be incorporated into a single product line, whether semi or fully automated. Multiple assembly cells can be arranged around a palletised transfer system, allowing for continuous, fully controlled assembly and testing, with the minimum number of operators needed. Pallet systems have included poka yoke assembly cells, vision inspection, robot pick & place, robotic automated screwfeed systems, laser marking, end of line testing, leak detection, LCD display testing, label print and apply systems and many other processes. For many customers, hot plate welding is the preferred method of bonding two parts together and once again, ALPHR have been able to bring our experience and knowledge to many projects. With our in-house tool room, we have the facilities to manufacture basic heat plates or complex mirrors and then integrate these into automated machines using contact or non-contact techniques. For Rotary Assembly Leak Test Machines, see page 17 11

12 Poka Yoke Assembly Station ALPHR Technology are helping our customers strive for production perfection, eliminating failures and ensuring non-conforming products don t reach the end user. Whether on simple assembly benches or fully automated production lines, Poka Yoke tooling helps control the assembly process so mistakes can t be made. Combining quality made, in-house tooling, various sensors, simple vision sensor technology or full functionality machine vision for more complex inspection tasks, our tooling is designed and manufactured to control the assembly process and ensure our customers exacting standards are met. Our own in-house machine shop is staffed with toolmakers and machinists capable of producing tooling not only to the highest quality, but which will last the lifetime of the machines. We all know that parts change, it s a fact of life in manufacturing, but our in-house facilities allow modifications and customer requests to be accommodated and dealt with in a timely fashion. Poka Yoke tooling, coupled with a PC control system, allows the assembly process to be fully controlled, both mechanically and by prompting and indicating to the operator exactly what the next step of the process is. Our software package displays images/photos during the assembly process and can even display work instructions, only progressing if certain criteria is met. By controlling the assembly process with a combination of tooling and sensors, we can create an assembly cell that anyone can be trained to work on within a short time, ensuring that short-cuts cannot be taken.

13 Laser Marking & Cutting Assembly Benches ALPHR Technology has produced numerous machines where the customer required a method of part marking. In certain situations, paint marking can be seen as messy and engraving considered noisy, so as the cost of laser systems has reduced, they have become a more realistic alternative. Lasers offer a clean, quiet and quick solution to part marking and can be easily incorporated onto assembly stations, rotary machines and palletised assembly lines. At ALPHR Technology, we pride ourselves on selecting only the very best suppliers for our laser marking systems and have worked closely with companies such as Electrox for many years. This relationship offers us the ability to have trials carried out at the early stages of a project, allowing the correct equipment to be specified from the outset. Laser marking offers significant benefits, including: Quick marking times Clean process Clear, readable markings of alphanumeric, 1D and 2D barcodes and graphics Low maintenance The perfect assembly process doesn t always require rotary machines, fully automated assembly stations or conveyor lines, sometimes stand-alone assembly benches are the perfect choice. Where operator content is required, more often than not, lean line manufacturing layouts offer the practical solution. In over 26 years in automation, we have produced hundreds of assembly stations for a wide variety of customers and applications. Assembly benches can vary from simple press stations to manual assembly stations with component present and orientation sensing to ensure a correct and repeatable process. Benefits include: PC or PLC controlled Poka Yoke tooling Interchangeable tooling Benches can be linked together via Ethernet for controlled assembly or each bench can report back to a central control system. Operator prompts including pictures/graphics Flexible design to accommodate any customers requirements Easily programmable for changes and future variants As well as laser marking, ALPHR have worked closely with our customers to develop laser cutting and routing systems onto production lines. PCB separation from multiple panels requires a laser to cut through the substrate and release the product from the carrying frame. Complete systems include de-stacking, auto loading, waste handling and transfer to process. Fast, efficient and dust free, laser cutting provides a significant step forward from traditional mechanical cutting techniques. Laser cutting is a virtually silent process, thus eliminating noise concerns associated with traditional routing techniques. 13

14 Vision Inspection At ALPHR technology, we can truly say that we specialise in vision inspection. To be successful in this field, industry experience and knowledge are vital to provide the often niche requirements in specific industries. With a proven track record of providing robust and innovative inspection solutions to the global automotive sector, ALPHR technology can realise solutions, from simple Poka Yoke test stations to advanced inspection and handling stations. ALPHR Technology are proud to be associated with our vision partners Omron and Cognex.

15 Vision Gauging Systems Part Present Vision Checking Poka Yoke Assembly Checks with Vision Systems As vision technology has progressed, the ability to measure and check for features and marks on a product has improved dramatically. A wide range of vision systems have been used by ALPHR Technology to gauge a variety of products, including plastic mouldings, fuel rails, metal spacers and metal inserts. Tests have included length, width, diameter, bore diameter, clearance, feature checking, position checking and checks for marks, dents and scratches. Vision systems offer a high speed, non-contact, multi-point checking system, reducing the need for multiple contact and laser sensors, therefore offering the potential of a lower cost gauging system. Before any test or assembly process can start, there must be some form of checking to ensure a part is actually present in the fixture. Historically, proximity or beam sensors have been used but with the advent of low cost vision sensors, a more reliable and flexible solution is now available. ALPHR Technology have experience using vision sensors from Cognex, Omron and Keyence, allowing not only simple part present checks to be carried out but also checks for orientation, correct loading and additional part inspection. Using more advanced vision checking systems at the start of an assembly process reduces failures by catching potential errors at the beginning of the sequence. ALPHR Technology manufacture bespoke manual/ semi-automated assembly stations providing Poka Yoke inspection. We utilise simple vision sensor technology for checking orientation, presence and correctness, as well as full functional machine vision for more complex inspection tasks. Integrating machine vision inspection into existing processes allows manufacturers to ensure product quality and improve reliability. Vision gauging systems have been used by ALPHR Technology on assembly benches, rotary machines, pallet systems and on robot gauging stations where the cameras are mounted directly to the robot and moved around the part. As robots and vision systems reduce in cost, robot vision inspection is becoming far more viable, offering cost effective and flexible gauging solutions. Vision sensors can dramatically reduce the mechanics and wiring around a load station, allowing easier access for an operator and a less complicated station. ALPHR Technology has many years experience in gauging systems, not only with vision systems but also with laser sensors, LVDTs and micrometres and can offer advice on the most effective solution for your requirement. 15

16 Leak Detection & Flow Measurement For over 26 years, ALPHR have been manufacturing leak detection and flow test stations for a wide range of customers and applications. The experience gained allows us to assess the best test method for a product and offer recommendations on test pressures, flow rates and leak rates. By working closely with suppliers who are experts in this field, such as Furness Controls, we are able to not only offer advice, but also assist with product trials to ensure complete confidence in the systems we supply. Leak detection has a number of anomalies that need to be taken into account on any test machine, whether manual or automated, but our experience gained in such a wide variety of products over many years ensures that ALPHR Technology fully understand the requirements of leak detection and flow measurement and can offer systems that are second to none in terms of performance, reliability and quality.

17 Products Tested Include: Robotics and Leak Detection Rotary Assembly Leak Test Machines Automotive plastic moulding Vehicle headlights Solenoids Proportional valves Domestic boiler heat exchangers Domestic boiler gas valves and circuits Domestic boiler case leak tests Domestic boiler flow tests Domestic boiler combustion leak tests Automotive air boxes Fuel pumps Fuel pump fittings Wine dispensing valves Drink dispensing systems Fuel lines Fuel tanks Medical inhalers Fuel rails Inlet manifolds Exhaust systems Brake callipers Leak detection is generally carried out after some form of assembly process, whether adding parts or fitting seals. ALPHR have produced a wide range of machines which integrate robots into the manufacture and test process, from transferring the parts to a dedicated leak test station on a rotary or palletised machine, to the robot actually assembling the part and using its tooling or gripper to create a seal. Robots can help reduce the number of operators and allow for more complex tasks, such as part manipulation or sealing to be done in parallel with other processes. Areas which are mechanically awkward for standard tooling to access can be easily reached with the flexibility of the robot. The most common application for robots in leak detection is the transfer of parts off a rotary machine when the part is awkward or impossible to seal on the rotary table itself. The part can be removed from the nest and placed onto a dedicated leak test fixture for the duration of the leak test cycle. On completion, the part can be transferred back on to the rotary table if further processes are required. Rotary test machines offer a flexible assembly and test process with minimal operators or operator input. A large proportion of our rotary machines encompass leak detection or flow measurement of the product, either on the rotary table or as a separate test station. The fixture and sealing is critical to the success of leak detection with dead-stops, polyurethane moulded seals and expanding seals often being required to correctly test a product. Rotary machines allow for sealing and testing of the product, whilst still allowing other assembly processes to continue in parallel. Our many years of experience gives us a significant advantage in understanding how to reduce cycle times and remove the side effects often associated with either the product or automating leak detection. Various cast products Whether Cartesian, SCARA or six axis, robots are fast becoming a cost effective and reliable alternative to operators or traditional transfer systems. 17

18 Flow Measurement High and Low Test Pressures For many products, checking the flow rate through a pipe/bore or checking for blockages and inclusions is an important part of the test/assembly process. Over the years, ALPHR has produced test/assembly machines for many companies testing the flow rate of products ranging from: Domestic boilers Fuel lines Hydraulic lines Castings Medical devices Solenoids and valves A wide variety of tests with many different media ranging from air, gas and fluids have been carried out on these parts, including: Products used with hydraulics, such as braking systems, require test pressures that are beyond the range of many leak detectors. For pressures ranging from 30bar to +200bar, a more bespoke system is generally required. Therefore, ALPHR Technology have designed and manufactured a number of high pressure test systems into automated assembly machines. By selecting only the highest quality leak-tight pressure sensors and transducers, we ve been able to produce test machines capable of accurate measurement of leak rates at high pressures. For a customer to select an automation company for this type of project, they must ensure the supplier not only has experience in this field, but also understands the fundamentals of high pressure testing and the safety factors surrounding it. ALPHR Technology has a proven track record in this field and we re happy to work with our customers to develop assembly and test processes for individual requirements. Gas flow rates Case leak tests Combustion chamber checks Blockage checks Flow rates through a solenoid Flow rates through medical drug delivery systems Flow rates of fuel pumps and fuel lines The equipment used has been very specific to the customers requirements, often requiring trials or ALPHR s experience to establish correct test methods. ALPHR have not only integrated stand- alone flow equipment from suppliers such as ATEQ and Furness Controls, but also developed flow test systems based on mass flow devices and incorporated them into our software/plc based systems. By using our own experience and the knowledge of our leading suppliers, ALPHR are able to ensure our customers receive the right equipment for their requirements.

19 Pressure Decay Leak Detection Machines For many products used with oil, water, fuel and air, the integrity of the parts is critical to its performance. Technology has progressed from the old fashioned method of air-under-water testing and looking for bubbles, to today s more advanced air pressure decay testers. Offering higher test pressures and more accurate measurement, leak detectors such as those supplied by Furness Controls can offer a clean, quick, reliable and accurate method of leak detection. ALPHR Technology has manufactured numerous leak detection stations during its 26 years, with Furness Controls and ATEQ being favoured suppliers for the duration. By understanding the dynamics of leak detection on a product and with years of experience integrating leak testers, ALPHR Technology have gained an excellent reputation as experts in this particular field. Our extensive portfolio of leak tested parts includes injection moulded parts, castings, headlights, inhalers, solenoids, valves, brake systems, fuel systems, fuels pumps, oil pumps, syringes and domestic boilers, to name a few. Industries include automotive, medical, defence and domestic white goods. From stand-alone test benches supplied with simple tooling, to complete assembly lines with multiple leak detection stations, ALPHR Technology has the knowledge and expertise to help with any application and bring an unprecedented amount of experience to a project. 19

20 Amor Way, Dunham s Lane, Letchworth Garden City, Herts SG6 1UG Tel +44 (0) Fax +44 (0) enquiries@alphrtechnology.co.uk