Here at VDL ETG Almelo, we manufacture many high-tech systems and modules for the semiconductor industry. Common components of these systems are large aluminium frames (amongst other products and systems). Other components are typically joint together using bolts. Although very light, aluminium is also a relatively soft material. Therefore, the joints would be fragile if bolts are screwed directly into the aluminium, especially when parts get assembled and reassembled often. The strength requirements of our customers is often considerably higher, so in order to mitigate this problem, we use inserts like helicoils and keenserts made from stainless steel, which greatly increases the strength of the bolted joint. These inserts are placed into holes in the aluminium. Helicoils are screwed in, while keenserts get secured into the aluminium using pins.

The inserts are currently placed and checked manually. Tens to hundreds or even thousands of inserts are placed within each frame, and the mentioned standard of quality requires that each insert is double-checked by a colleague. It’s important to double check that the helicoil or keensert is placed correctly in the correct spot. This is a time consuming manual process, which we think could be improved significantly with your help.

Two case challenges can be derived from this manufacturing process:

• The placement of the inserts: How to automate placement?
• The inspection of the inserts: How to validate placement?