Multi-Robot Automated Assembly Cell with Vision Control

Iskra PRO designed and built a fully automated, robot-assisted assembly system for a leading appliance manufacturer. The solution handles multiple product variants with integrated vision systems, grease dosing, and intelligent quality control — replacing manual labor while increasing throughput and precision.

Client Needs & Project Goals

A global home appliance producer approached Iskra PRO with a clear objective: to create a highly automated, flexible assembly solution capable of handling several product variants — while reducing manual labor, increasing repeatability, and ensuring defect-free quality.

The key goals included:

Full subassembly of components made up of 11–13 individual parts
Advanced robotic handling with precision and repeatability
Vision-guided inspection and dynamic adjustment of assembly steps
Reliable feeding via vibratory bowls and pallet exchange
Elimination of human error and increased production uptime

This solution had to comply with industry safety and quality standards while maintaining efficiency and scalability for future product types.

“We needed flexibility and consistency — Iskra PRO delivered both. Their system helped us scale efficiently while improving quality at the same time.”

Technical Overview & Implementation Details

Key system specifications:

Product variants: 3 different models
Part count per product: 11–13 components
Cycle time: 11.5 seconds per unit
Output: approx. 2,350 pieces/shift
Autonomy: ~2 hours of operation without intervention
Labor reduction: replaces 5–6 manual stations

The system developed by Iskra PRO is a modular, robot-assisted assembly cell with full-cycle automation. It integrates:

ABB robots with pneumatic dual grippers
Multiple vibratory feeders
A high-speed rotary table assembly system
Servo-driven screwing and dosing units
Four independent camera-based inspection systems
A pallet exchange system for bulk part loading

Automated Valve Assembly Cell by Iskra PRO

Step-by-Step Assembly Process

1. Manual Loading Station

- Operator inserts 2 parts into base housing.

2. Lower Assembly (8-station rotary table)

- Vibratory bowls feed components to nests.
- Press-fit bearing using pneumatic press
- Insert spring leaf
- Transfer to upper table

3. Upper Assembly (12-station rotary table)

- Robotic feeding into spring-loaded nests
- 6 progressive assembly stations (robot-assisted)
- Camera detects orientation and adjusts grip
- Grease dosing on screw paths
- Servo screwdriving with torque feedback
- Shape detection and mismatch rejection