Light Lens Assembly and Ultrasonic Welding for Aerospace Manufacturing

All-Phase Companies developed a fully automated material handling solution featuring the FANUC CR-15iA collaborative robot. This system was engineered to streamline the production of light dispersion lenses, combining precision robotics with ultrasonic welding for a seamless, lights-out manufacturing process.

How the System Works:
The process begins with the robotic infeeding of clip trays into the cell, triggering the automated lens assembly process. A flying saw then cuts each light dispersion lens to the required length, after which the cut lens is placed onto the infeed conveyor. The FANUC CR-15iA cobot picks the lens from the conveyor and positions the first clip, which is immediately welded by an ultrasonic welder. The robot then places the second clip, which is also welded in place using the same ultrasonic technology. Once both clips are welded, the robot transfers the completed lens to the outfeed cart, completing the cycle.

Key Benefits:
• One-Minute Cycle Time: Delivers consistent throughput with a fully automated 60-second cycle.

• Labor Optimization: Replaces multiple temporary workers with a single full-time operator, significantly reducing labor costs and improving consistency.

• Custom 3D-Printed End Effectors: Tailored grippers enhance handling precision and reduce part changeover time.

About ‪@All-Phase‬
All-Phase Companies formerly known as All-Phase Electric, Inc., has been serving the central Washington area since 1996. We are locally owned and operated with two locations, Yakima and Wenatchee. We offer commercial and industrial electrical and engineering services that are affordable, reliable, and safe. No project is too large or too small for us. If you have a challenge, we have a solution!

FANUC CR-15iA Collaborative Robot - https://bit.ly/3GJZiW8
With a payload capacity of 15 kg, this collaborative robot bridges the gap between smaller CR models and the larger CR-35iB. Built on FANUC’s proven technology and equipped with a highly sensitive base-mounted sensor, it delivers exceptional reliability and safety. Designed to operate seamlessly alongside human workers, it excels in a variety of industrial tasks—including material handling, machine tending, inspection, and logistics.

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