Engineered to increase throughput, improve coating consistency, and eliminate the maintenance challenges associated with manual electrical compound application
A manufacturer of electrical compression connectors relied on an aging coating process used to apply anti-oxidant electrical compound to copper connectors prior to shipment. While functional, the legacy system had become a major bottleneck within production operations. The process utilized a shellac-based adhesive spray system combined with metallic compound application that created significant maintenance and housekeeping challenges. Operators were required to stop production frequently for cleaning due to material buildup throughout the machine. Spray nozzles regularly clogged, filters required constant replacement, and ventilation system failures created additional downtime and operational complexity. Product quality also suffered from inconsistent coating coverage, requiring manual inspection and increasing labor requirements.
Beyond maintenance concerns, the client needed to increase production capacity while supporting multiple connector sizes and product variants. The new system needed to achieve throughput rates of 3,600 parts per hour, reduce cleanup time to less than 15 minutes per shift, simplify changeovers, and provide consistent coating quality across multiple SKUs. The client partnered with Re:Build DAPR to develop a fully automated coating and inspection system capable of transforming a labor-intensive process into a reliable, high-throughput manufacturing platform.
Re:Build DAPR began by evaluating the existing process and identifying the primary sources of downtime, quality variation, and maintenance burden. The engineering team focused on replacing the outdated shellac-based application method while preserving the anti-corrosion performance required for the finished product.
A significant portion of the project involved researching alternative adhesive formulations and evaluating new methods for applying the dry electrical compound. Multiple proof-of-concept approaches were developed and tested to identify a solution that could deliver reliable coverage without the clogging, overspray, and contamination issues associated with the previous process.
The team also developed a complete automated material handling strategy capable of supporting high production rates. This included vibratory feeding systems, controlled adhesive application, UV curing, in-motion quality inspection, reject handling, and automated part accumulation. Careful attention was given to simplifying maintenance activities, minimizing wear components, and reducing operator intervention throughout the process.
Re:Build DAPR designed and built a fully automated electrical compound application system optimized for throughput, consistency, and ease of operation. The system begins with a vibratory bowl feeder and bulk hopper that orient and deliver copper compression connectors into the production line. A precision micro-spray adhesive system applies a controlled coating using a cartridge-based dispensing platform that simplifies material handling and cleanup. Following application, parts pass through an integrated UV curing tunnel that rapidly cures the adhesive while maintaining operator safety through interlocked guarding.
To address the challenges associated with dry compound application, Re:Build DAPR developed an innovative electromagnetic deposition system. Dual vibratory feeders deliver anti-oxidant electrical compound through custom 3D-printed nozzles, while electromagnetic applicators precisely attract and position the material onto targeted surfaces of the connector. This approach eliminates many of the clogging, contamination, and maintenance issues associated with conventional coating methods.
After compound application, parts travel through a dual-speed conveyor system where vision sensors inspect coating quality in motion. Non-conforming parts are automatically removed using a pneumatic reject station, while accepted parts are routed to a rotary accumulation system that maintains continuous operation during packaging changeovers. The entire platform is controlled through a Rockwell CompactLogix automation architecture with integrated safety controls, allowing operators to manage production efficiently while supporting rapid SKU changeovers.
Re:Build DAPR successfully delivered an automated coating platform that dramatically improved production efficiency, quality, and operational reliability. The new system achieved the client’s target throughput of 3,600 parts per hour while reducing cleanup requirements from approximately 30 minutes every production hour to just 15 minutes at the end of an eight-hour shift. Automated inspection eliminated the need for continuous manual quality verification, while controlled adhesive application and electromagnetic compound deposition significantly improved coating consistency.
The cartridge-based adhesive delivery system simplified maintenance activities, reduced material waste, and minimized downtime associated with cleaning and consumable replacement. In addition, SKU changeovers were reduced to approximately ten minutes, enabling greater production flexibility and responsiveness. The project transformed a labor-intensive, maintenance-heavy process into a scalable automated manufacturing solution that improved quality, reduced operating costs, and increased overall production capacity.
The automated electrical compound application system included:
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