Project Overview

TCI Engineering developed a fully automated production line designed to optimize terminal adapter manufacturing. The system combines state-of-the-art robotics, precise material handling, and integrated quality control to enhance efficiency and maintain high product standards.

Objective

The goal of this project was to streamline the production process for terminal adapters by implementing an automated system that minimizes manual intervention while ensuring consistent quality and reliability.

Solution

To meet the client’s high standards and production demands, TCI Engineering delivered a robust and intelligent automation system combining precision, speed, and flexibility.

Key components of our solution:

• Six-axis robotic arm for dynamic loading/unloading of the injection molding press
• SCARA robot managing delicate insert handling and quality testing via a rotary station
• Custom grippers with independent vertical movement for accurate, damage-free part manipulation
• Automated insert preparation using a de-reeler and cutting press, minimizing manual labor
• Blister conveyor system for organized output conditioning and part flow control

Seamless software integration tied all components together, enabling synchronized operations and real-time performance monitoring.

Implementation

TCI Engineering designed and installed a fully integrated automation layout. This involved constructing a dual-robot system tailored to the client’s specific manufacturing requirements, integrating mechanical, electrical, and software components for maximum performance. The team conducted extensive testing and fine-tuning to optimize functionality and trained operators to ensure smooth operation after deployment.

Results

The completed system delivered measurable improvements across multiple performance areas:

• Production time reduced significantly, accelerating output without compromising precision
• Enhanced product consistency and quality thanks to automated, repeatable testing
• Improved operator safety by minimizing manual interaction with machinery
• Easy-to-maintain system with modular components and intuitive operator interface

This project is a prime example of how TCI Engineering transforms complex manufacturing challenges into streamlined, high-performance automation solutions.