A

Project Report On

“Phases of Mobile Manufacturing and Custom

Machines Troubleshooting”
(Under- “Industry Internship &Project” Track)
Submitted
in partial fulfillment of the requirements for the degree of
Bachelor of Technology
in
Mechatronics Engineering
by
Mr. Rakshit Sanjay Pansande (2015031)

At
Wipro Pari Robotics Pvt. Ltd. Shirwal

Under the Guidance of

Prof. A. B. Chavan

Mechatronics Engineering Department

K. E. Society’s
Rajarambapu Institute of Technology, Rajaramnagar
(An autonomous Institute, Affiliated to Shivaji University)

2023-2024
 K. E. Society’s
Rajarambapu Institute of Technology, Rajaramnagar
(An Autonomous Institute, Affiliated to Shivaji University)
Department of Mechatronics Engineering

CERTIFICATE

This is to certify that the internship under Industry Internship & Project (IIP) track completed at
“Wipro Pari Robotics Pvt. Ltd. , Shirwal” is the bona fide work submitted by the following student,
to the Rajarambapu Institute of Technology, Rajaramnagar during the academic year 2023-24, in
partial fulfillment for the award of the degree of B. Tech in Mechatronics Engineering under our
supervision. The contents of this report, in full or in parts, have not been submitted to any other
Institution or University for the award of any degree.

Name of Students Roll Number

Rakshit Sanjay Pansande 2015031

Date: 10/06/2024
Place:Rajaramnagar

Prof. A. B. Chavan Mr. Settu V Samraj

Industry Internship & Project Mentor Industry Internship & Project
(College) Mentor(Industry)

External Examiner

Prof. S. S. Deshmukh Dr.S.S.Shirguppikar

Training &Placement Coordinator Head of Department
i
 DECLARATION

I declare that this report reflects my thoughts about the subject in my own words. I have sufficiently
cited and referenced the original sources, referred to or considered in this work. I have not
plagiarized or submitted the same work for the award of any other degree. I also declare that I have
adhered to all principles of academic honesty and integrity and have not misrepresented or
fabricated or falsified any idea/data/fact/source in my submission. I understand that any violation
of the above will be cause for disciplinary action by the Institute.

Sr. No. Student Name Roll No Signature

1. Rakshit Sanjay Pansande 2015031

Date: 10/06/2024

Place: RIT, Rajaramnagar.

ii
 ACKNOWLEDGEMENT

I take this opportunity to thank all those who have contributed to the successful completion of an
Internship Under the Industry Internship & Project (IIP) track at “Wipro Pari Robotics Pvt. Ltd.,
Shirwal.”. I sincerely wish to express my gratitude to Industry Internship & Project (IIP) Mentor
Prof. A.B. Chavan for full support, expert guidance, encouragement, and kind cooperation
throughout the Internship work. I am greatly indebted to him for his help throughout the project
work. I express my sincere gratitude towards Dr. S.S. Shirguppikar Head of the Department, of
Mechatronics Engineering, for providing the necessary facilities, guidance, and support.
I respect and thank Mr. Settu V Samraj for providing me with an opportunity to do a project in
Wipro Pari Robotics Pvt. Ltd. and giving us all support and guidance, which made me complete
the internship duly. I am extremely thankful to him for providing such nice support and guidance,
although he had a busy schedule managing corporate affairs.
I thank Prof. S.S. Deshmukh for providing an internship & Project Opportunity in an Industry.

I am thankful for and fortunate enough to get constant encouragement, support, and guidance from
all the Teaching staff of the Mechanical Engineering Department, which helped me in successfully
completing the internship.
Nevertheless, I express my gratitude toward my family members for their kind co-operation and
encouragement which helped me in the completion of this internship.

iii
 ABSTRACT

This internship report provides a comprehensive overview of the experience gained during an
internship at Wipro Pari Robotics Pvt. Ltd. in Shirwal. The report highlights the key tasks, projects,
and responsibilities undertaken, along with the knowledge and skills acquired the internship at
Wipro Pari Robotics Pvt. Ltd offered an opportunity to work closely with industry professionals
and gain practical insights into the operations of a leading energy pump manufacturing company.
The report begins by introducing the company, its mission, and its core products and services.

The main body of the report focuses on the specific projects and assignments undertaken during
the internship. These projects included conducting market research to identify potential growth
opportunities, analyzing competitor strategies, and assisting in the development of marketing
campaigns. Additionally, the report highlights the participation in cross-functional team meetings,
where insights were shared and collaborative problem-solving was conducted.

Furthermore, the report discusses the professional skills developed during the internship, such as
project management, data analysis, and effective communication. It also reflects on the application
of theoretical knowledge gained from academic studies and how it was applied to real-world
scenarios at Wipro Pari Robotics Pvt. Ltd.

The report concludes with a summary of the overall internship experience, including the personal
and professional growth achieved. It reflects on the challenges faced, the lessons learned, and the
valuable insights gained into the energy pump industry. Recommendations for future improvements
and suggestions to enhance the internship program at Wipro Pari Robotics Pvt. Ltd. are also
provided.

Overall, the internship at Wipro Pari Robotics Pvt. Ltd was a rewarding experience that provided
valuable industry exposure, practical skills development, and a deeper understanding of the energy
pump sector. This report serves as a comprehensive documentation of the internship period,
highlighting the achievements and contributions made during the internship while maintaining a
plagiarism-free approach.

iv
 CONTENTS

Certificate i
Declaration ii
Acknowledgment iii
Abstract
iv
Contents v

Chapter 1. Introduction

1.1 Introduction 1
1.2 Problem Statement 2
1.3 Objectives 2
1.4 Outline of project 3
Chapter 2. Mobile Assembly and Special Purpose machines (SPM)

2.1 Introduction 4
2.2 Advantages of utilizing SPM in mobile assembly processes 4

2.3 Theory of 5 ‘S’ 5

Chapter 3. Phases involved in mobile assembly

3.1 Overview of different phases involved in mobile assembly 6
3.2 Full equipment cycle plan 7
3.3 Components used 7
3.4 Final assembly 21
3.5 Testing and Quality Assurance 22
Chapter 4. Special Purpose Machines
4.1 Special Purpose Machines 25
4.2 Working principles of SPM in mobile assembly 26
4.3 Types of SPM used in mobile assembly 27
4.4 Importance of SPM in mobile assembly 28
Chapter 5. Maintenance Work 29
Chapter 6. Conclusion 42

LIST OF FIGURES
v
 List of Figures

Sr. No. Figure Name Page

No.
1 Overview of Stages in 6
Mobile Assembly
2 Reed Sensor 8
3 Photoelectric Sensor 9
4 Limit Sensor 9
5 Proximity Sensor 10
6 Fiber Optic Sensor 11
7 Stepper Motor 12
8 Servo Motor 12
9 Induction Motor 13
10 Cartesian Robot 14
11 SCARA Robot 15
12 Articulated Robot 16
13 Pneumatic Cylinder 17
14 Pneumatic Valve 17
15 CCD 18
16 Barcode Scanner 19

vi
Chapter 1
Introduction

1.1 Introduction

In the fast-paced world we live in today, mobile devices have become essential tools that seamlessly
integrate into our daily lives. Behind the sleek exterior of every mobile device lies a complex assembly
process that involves meticulous attention to detail and state-of-the-art machinery. Our training
session, "Different Phases of Mobile Assembly and Special Purpose Machines," aims to provide a
comprehensive understanding of the assembly process and the specialized machinery involved.
Whether you're an industry professional or an aspiring engineer, this training will offer valuable
insights into mobile technology.

The assembly of a mobile device involves several distinct phases, each crucial to the final product's
functionality and performance. It begins with component manufacturing, where individual parts like
circuit boards, display screens, and processors are produced using advanced techniques such as
injection molding and semiconductor manufacturing. These high-quality components are then
assembled into sub-assemblies, which form the core of the mobile device, using intricate processes
like soldering and bonding.

The final assembly phase brings together these sub-assemblies and components to create the complete
mobile device. Specialized techniques such as robotic assembly and automated screw tightening are
employed to streamline the process and minimize errors. Once assembled, each device undergoes
rigorous testing and quality assurance procedures to ensure it meets the highest standards of
performance, reliability, and safety.

At the heart of the mobile assembly process are specialized machines designed to perform specific
tasks with unparalleled precision and efficiency. These include pick-and-place machines for precise
component positioning, automated assembly lines for high-volume production, and testing equipment
for quality control. These machines play a critical role in optimizing production throughput and
product quality, ensuring that each mobile device meets the required standards before reaching the
hands of consumers.

R. I. T. Rajaramnagar 1
1.2 Problem Statement

Mobile device assembly requires precision and efficiency across multiple phases, from component
manufacturing to final testing. Understanding these phases and the specialized machines involved is
crucial for industry professionals and aspiring engineers. This training aims to provide comprehensive
knowledge of mobile assembly phases and the role of Special Purpose Machines (SPMs) in optimizing
production.

1.3 Objective

➢ To understand the various phases involved in mobile device assembly, from component
manufacturing to final product testing.
➢ To explore the specialized machinery used in each phase of mobile assembly.
➢ To learn about the role of pick-and-place machines, automated assembly lines, and testing
equipment in optimizing production throughput and product quality.
➢ To gain practical knowledge and valuable insights into mobile technology and assembly
processes.

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1.4 The project has following outline:

In this section the overall outline of the project has been discussed.
Chapter 1: Introduction
Chapter 2: Mobile Assembly and Special Purpose Machines (SPM)
-Significance of Mobile Assembly and Special Purpose Machines (SPM)
-Advantages of utilizing SPM in mobile assembly processes
-Theory of 5 ‘S’
Chapter 3: Mobile Assembly Phases
Overview of different phases involved in mobile assembly
-Different phases of mobile assembly
- Full equipment cycle plan
- Components used
- Final Assembly
- Testing and Quality Assurance
Chapter 4: Special Purpose Machines (SPM)
- Working principles of SPM in mobile assembly
- Types of SPM used in mobile assembly processes
- Importance of SPM in mobile assembly
Chapter 5: Maintenance Work
Chapter 6: Conclusion

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Chapter 2
Significance of Mobile Assembly and Special Purpose Machines (SPM)

2.1 Introduction

In today's fast-paced digital era, mobile devices have become essential components of our daily
lives, seamlessly blending into various aspects of our routines. However, behind their sleek
designs lies a complex assembly process that requires meticulous attention to detail and
efficiency. This is where the significance of mobile assembly and Special Purpose Machines
(SPM) becomes paramount.

Mobile assembly comprises several critical phases, ranging from component manufacturing to
final product testing. Each stage demands precision, speed, and consistency to meet the rigorous
performance and durability standards expected by consumers. Special Purpose Machines
(SPMs) play a pivotal role in optimizing this assembly process, enhancing efficiency, and
ensuring product quality.

SPMs are intricately designed and tailored to execute specific tasks with unparalleled precision
and efficiency. They automate repetitive tasks, minimize errors, and streamline the assembly
process. From pick-and-place machines, which accurately position components, to automated
assembly lines, which facilitate high-volume production, SPMs are indispensable in modern
mobile manufacturing facilities.

The integration of SPMs not only boosts production throughput but also enhances product
quality and consistency. By reducing manual intervention and human error, SPMs contribute to
cost savings and enhance competitiveness in the mobile device market. As mobile technology
continues to evolve and consumer demand grows, the significance of SPMs in mobile assembly
will only escalate, driving innovation and efficiency in the industry.

2.2 Advantages of utilizing SPM in mobile assembly processes:

The utilization of Special Purpose Machines (SPM) in mobile assembly processes offers several
significant advantages, enhancing efficiency, precision, and overall productivity.

Firstly, SPMs are specifically designed to perform particular tasks with unparalleled precision and

R. I. T. Rajaramnagar 4
efficiency. They automate repetitive tasks, minimize errors, and streamline the assembly process,
thereby increasing productivity and reducing manufacturing time.

Secondly, SPMs significantly reduce manual intervention and human error, leading to improved
product quality and consistency. By ensuring precise and accurate assembly, SPMs help meet the
stringent standards of performance, durability, and safety expected by consumers.

Thirdly, SPMs enhance flexibility and adaptability in mobile assembly processes. They can be easily
reconfigured or customized to accommodate changes in product design or manufacturing
requirements, allowing manufacturers to respond quickly to market demands.

Additionally, the integration of SPMs increases production throughput, leading to cost savings and
improved competitiveness in the mobile device market. By optimizing the assembly process and
minimizing production downtime, SPMs help manufacturers achieve higher output with lower
operating costs.

Overall, the advantages of utilizing SPMs in mobile assembly processes are numerous, including
increased efficiency, improved product quality, enhanced flexibility, and cost savings, making them
indispensable tools in modern mobile manufacturing facilities.

2.3 Theory of 5 ‘S’:

By implementing 5S system – ‘Sort’ , ‘set in order’, ‘Shine’, ‘Standardize’ & ‘Sustain’ organization
can create a Clean, well ordered and disciplined work environment.
Among companies implement only the first three steps. hoping the cost two will automatically follow.
1. Sort - Separate necessary items from unnecessary.
2. Set in order - Make a place for Everything & Everything. must have a proper place.
3. Shine - Clean up as you work & maintain a clean environment.
4. Standardize - Develop rule to repeat positive results.
5. Sustain - maintain consistency & strive for continued improvement.

R. I. T. Rajaramnagar 5
Chapter 3
Phases Involved in Mobile Assembly

This chapter describes various stages in mobile assembly. Various phases have been discussed in
upcoming subsections.

3.1 Overview of different phases involved in mobile assembly:

Figure 3.1 indicates different phases involved in mobile assembly.

Engineering Build. Operation Build.

Prototype Build Stage 0 Operation Validation Build

Prototype Build Stage 1

Process Readiness Build

Prototype Build Stage 2

Process and Production Validation
Test

Engg Validation Test

Production Validation Test

Carrier Readiness Build

Engg build to Mass production

Design Validation Test

Production Validation Test Mass Production

Figure: 3.1 Overview of Stages in Mobile Assembly

R. I. T. Rajaramnagar 6
3.2 Full Equipment Cycle Plan.

1. Based on the Product design customer will approve the design of the Equipment based on there
end application requirement during the Stage both customer and internal R&D team will Co-work
and develop the Solution.

2. Categories-

a. Engineering Build Equipment-These EQs will be used only during the Engineering build of a
new generation product.

b. DCO (design carry over)-Based on the new generation Product sometimes, there will be DCO
of the Same Equipment Without ang Change from current to the new generation Product.

c. New development To improvise the Perfection, efficiency and reduce the errors, customer and
System Integrator will co-work and develop a new automation Solution (In other words-
Converting manual to Automated operations OR implementing new automation Stage based on
the product needs.

d. RF (Retrofit) Based on the new generation Product design. R&D team will evaluate the
Feasibility converting the older generation Equipment to Next generation Equipment Converting
the Current version EQs to the new generations versions.

3.3 The machine has following components:

3.3.1 Sensor.
3.3.2. Motors
3.3.3. Robot.
3.3.4. Pneumatic Cylinder and Value.
3.3.5.CCD.
3.3.6. Bar Code Scanner.
3.3.7. IPC.
3.3.8. Vision System.
3.3.9. Motion Controller.

3.3.1 Sensor: Sensors are critical components in mobile assembly processes, playing a vital role in
ensuring product quality, performance, and user experience. These devices detect and measure various
parameters during the assembly process, providing valuable feedback to control systems and operators. One

R. I. T. Rajaramnagar 7
of the primary advantages of sensors in mobile assembly is their ability to provide real-time data
on key parameters such as position, force, pressure, temperature, and alignment. This data allows
for precise control and monitoring of the assembly process, ensuring that components are correctly
positioned, secured, and functioning as intended.

Types of sensors used:

a. Reed switch:
Reed switches are crucial components used in various stages of mobile assembly processes due to
their reliability, versatility, and ease of integration. These switches consist of two ferromagnetic
contacts housed within a hermetically sealed glass envelope, making them highly resistant to
environmental factors such as dust, moisture, and vibration.
One of the primary uses of reed switches in mobile assembly is for proximity sensing and position
detection. They are employed to detect the opening and closing of mobile device covers, ensuring
proper alignment and secure closure. Additionally, reed switches are used to detect the presence or
absence of components during the assembly process, ensuring accurate placement and alignment.
Reed switches are also utilized for motion detection and limit switching in mobile assembly lines.
They help monitor the movement of conveyor belts, robotic arms, and other machinery, ensuring
smooth operation and preventing collisions or jams. By providing accurate and reliable feedback,
reed switches contribute to the efficiency and safety of the assembly process.

Fig. 1. Reed Sensor

b. Photoelectric sensor:
Photoelectric sensors are essential components in mobile assembly processes, providing non-
contact detection of various objects and components with high accuracy and reliability. These
sensors utilize light beams to detect the presence, absence, or position of objects, making them
invaluable for a wide range of applications in mobile device manufacturing.

R. I. T. Rajaramnagar 8
One of the primary uses of photoelectric sensors in mobile assembly is for component detection and
alignment. They are used to verify the presence and correct placement of components such as circuit
boards, display screens, and camera modules during the assembly process. By ensuring accurate
alignment and placement, photoelectric sensors help prevent assembly errors and ensure product
quality

Fig. 2 Photoelectric Sensor

c. Limit sensor:
Limit sensors, including reed switches, are essential components in mobile assembly processes,
serving various functions to ensure precision, safety, and efficiency.
Position Sensing: Limit sensors are used to detect the position of moving parts, ensuring they are in
the correct location before the next assembly step. For example, in mobile assembly, limit sensors
ensure that components are properly aligned before they are assembled, preventing errors and
ensuring product quality.
Motion Control: Limit sensors help control the motion of machinery in the assembly line. By detecting
the presence or absence of objects, they ensure that machinery operates only when it is safe to do so,
preventing accidents and damage to equipment.
Monitoring: Limit sensors play a crucial role in ensuring the safety of the assembly process. They can
detect the presence of objects in hazardous areas and shut down machinery to prevent accidents.

Fig. 3 Limit Sensor

R. I. T. Rajaramnagar 9
 d. Proximity sensor:
Proximity sensors play a crucial role in mobile assembly processes, offering numerous benefits that
enhance efficiency, accuracy, and overall productivity.
One of the primary uses of proximity sensors in mobile assembly is for position detection and
alignment. These sensors accurately detect the presence or absence of components, ensuring proper
placement and alignment during the assembly process. For example, proximity sensors are used to
detect the opening and closing of mobile device covers, ensuring secure closure and proper alignment
of components.

Fig. 4 Proximity Sensor

e. Fiber optic sensor:
Fiber optic sensors are integral components in mobile assembly processes, offering unique advantages
that contribute to efficient and reliable manufacturing.One of the primary uses of fiber optic sensors
in mobile assembly is for precise and non-contact measurements. These sensors utilize light to detect
changes in position, displacement, pressure, temperature, and other parameters with high accuracy
and sensitivity. In mobile assembly, fiber optic sensors are commonly used for:

1. Alignment and Positioning: Fiber optic sensors ensure accurate alignment and positioning of
components during assembly. They can detect minute changes in position, ensuring precise
placement and alignment of critical components such as circuit boards, displays, and cameras.

2. Quality Control and Inspection: Fiber optic sensors are used for quality control and inspection
purposes during the assembly process. They can detect defects, irregularities, or discrepancies
in components or assemblies, ensuring that only high-quality products reach the market

R. I. T. Rajaramnagar 10
 Fig. 5 Fibre Optic Sensor

3.3.2. Motor:
a. Stepper Motor.
b. Servo Motor.
c. Induction Motor.

a. Stepper motor:
Stepper motors are essential components in mobile assembly processes, offering precise control, high
reliability, and versatility. These motors convert digital pulses into mechanical rotation, making them
ideal for a wide range of applications in mobile device manufacturing.

One of the primary uses of stepper motors in mobile assembly is in robotic arms and automated
machinery. These motors provide precise control over the movement of robotic arms, allowing for
accurate positioning and manipulation of components during the assembly process. By controlling the
rotation and movement of conveyor belts, stepper motors enable smooth and efficient transfer of
components between different stages of the assembly line.

Stepper motors are also used in the assembly of mobile device components such as circuit boards,
displays, and cameras. They provide precise control over the positioning and alignment of these
components, ensuring accurate placement and soldering. This helps maintain the quality and
reliability of the finished mobile device, reducing the risk of defects and malfunctions.

R. I. T. Rajaramnagar 11
 Fig. 6 Stepper Motor

b.Servo motor:
Servo motors are critical components used in various stages of mobile assembly processes due to their
precision, control, and efficiency. These motors offer unique advantages that contribute to reliable
and high-quality manufacturing. One of the primary uses of servo motors in mobile assembly is for
precise motion control and positioning. They are employed to accurately move and position
components during the assembly process, ensuring proper alignment and fit.

Servo motors offer high precision and repeatability, making them ideal for tasks that require accurate
and consistent movement, such as robotic assembly, conveyor belt control, and pick-and-place
operations. Another important use of servo motors in mobile assembly is for testing and quality
assurance. They are used to simulate real-world conditions and perform functional tests on mobile
devices, ensuring that they meet the required performance and reliability standards. Servo motors
enable manufacturers to conduct rigorous testing, identify defects or malfunctions, and rectify them
before the devices reach consumers.

Fig. 7 Servo Motor

R. I. T. Rajaramnagar 12
c. Induction motor:
Servo motors are critical components used in various stages of mobile assembly processes due to their
precision, control, and efficiency. These motors offer unique advantages that contribute to reliable
and high-quality manufacturing. One of the primary uses of servo motors in mobile assembly is for
precise motion control and positioning. They are employed to accurately move and position
components during the assembly process, ensuring proper alignment and fit. Servo motors offer high
precision and repeatability, making them ideal for tasks that require accurate and consistent
movement, such as robotic assembly, conveyor belt control, and pick-and-place operations. Another
important use of servo motors in mobile assembly is for testing and quality assurance. They are used
to simulate real-world conditions and perform functional tests on mobile devices, ensuring that they
meet the required performance and reliability standards. Servo motors enable manufacturers to
conduct rigorous testing, identify defects or malfunctions, and rectify them before the devices reach
consumers.

Fig. 8 Induction Motor

3.3.3 Robot:
Cartesian, SCARA, and articulated robots are essential components in mobile assembly
processes, offering precision, flexibility, and efficiency. Each type of robot has its own
unique capabilities and advantages, making them suitable for specific tasks in mobile
device manufacturing.

1.Cartesian Robots:
Uses:
1. Cartesian robots are commonly used for pick-and-place operations in mobile assembly, where
they accurately position components during the manufacturing process.
2. They are also utilized for packaging and palletizing finished mobile devices, ensuring efficient

R. I. T. Rajaramnagar 13
 and reliable handling of products.
3. Importance:
4. Cartesian robots offer high precision and repeatability, ensuring consistent and accurate
assembly of mobile devices.
5. Their simple design and easy programming make them versatile and cost-effective solutions
for a wide range of assembly tasks.
6. Cartesian robots help improve productivity and efficiency by automating repetitive tasks and
reducing cycle times in the assembly process.

Fig. 9 Cartesian robot

2. Scara Robots (Selective Compliance Assembly Robot Arm):

Uses:
1. SCARA robots are commonly used for tasks that require fast and precise horizontal
movements, such as screwing, soldering, and gluing components in mobile devices.
2. They are also used for material handling, loading and unloading components, and transferring
products between different stages of the assembly process.
Importance:
1. SCARA robots offer high-speed operation and precise positioning, making them ideal for
applications that require fast and accurate assembly.
2. Their compact design and small footprint make them well-suited for use in confined spaces,
maximizing floor space in mobile assembly facilities.
3. SCARA robots help improve production efficiency, reduce cycle times, and ensure the
consistent quality of mobile devices.

R. I. T. Rajaramnagar 14
 Fig. 10 SCARA Robot
3. Articulated Robots:
Uses:
Articulated robots are used for a wide range of tasks in mobile assembly, including material handling,
welding, painting, and inspection.
They are particularly well-suited for applications that require complex movements and precise
positioning, such as assembling intricate components or performing detailed inspections.
Importance:
1. Articulated robots offer maximum flexibility and versatility, allowing them to perform a wide
range of assembly tasks with high precision and efficiency.
2. Their multi-axis design enables them to reach into tight spaces and access hard-to-reach areas,
making them ideal for assembling complex mobile devices.
3. Articulated robots help manufacturers improve productivity, reduce labor costs, and maintain high
product quality by automating assembly processes and reducing human error.
4. Overall, Cartesian, SCARA, and articulated robots are indispensable tools in mobile assembly
processes, offering precision, flexibility, and efficiency. By automating repetitive tasks, improving
productivity, and ensuring the consistent quality of mobile devices, these robots help
manufacturers meet the demands of a rapidly evolving market and deliver high-quality products to
consumers.

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 Fig. 11 Articulated Robot

3.3.4. Pneumatic cylinder and valve:

Single-acting solenoid valves are commonly used in mobile assembly for applications where a spring
return is sufficient to return the valve to its default position. They are utilized for tasks such as
controlling the flow of air, liquids, or other fluids in pneumatic systems. Single-acting solenoid valves
are important for tasks like controlling the movement of robotic arms, actuating clamps, or controlling
the flow of air to pneumatic actuators. Double-acting solenoid valves are used when both the opening
and closing of the valve require the application of pressure. They offer precise control over the
direction of flow and are commonly used in applications where the valve needs to remain in its current
position until acted upon by the control system. In mobile assembly, double-acting solenoid valves
are used for tasks such as controlling the movement of hydraulic cylinders, actuating grippers, or
controlling the flow of air to pneumatic actuators.

Pneumatic cylinders are used extensively in mobile assembly processes for tasks that require linear
motion or force generation. They are often used in conjunction with solenoid valves to provide precise
control over the movement of robotic arms, conveyor belts, and other automated equipment.
Pneumatic cylinders are also used for tasks such as clamping, lifting, pushing, and pulling components
during the assembly process.

R. I. T. Rajaramnagar 16
The importance of single and double-acting solenoid valves and pneumatic cylinders in mobile
assembly processes cannot be overstated. Their ability to provide precise control, reliability, and
versatility makes them indispensable components for ensuring the smooth operation of assembly
lines, the precise assembly of components, and the quality control of mobile devices. By providing
precise control over the movement of components and equipment, these components help optimize
production processes, minimize errors, and ensure the timely delivery of high-quality mobile
devices to consumers.

Fig. 12 Pneumatic Cylinder

Fig. 13 Pneumatics Valve

3.3.5 CCD
Charge-Coupled Devices (CCDs) are essential components in mobile assembly processes, offering
precise imaging and inspection capabilities that ensure product quality and performance. CCDs are
widely used for various applications in mobile device manufacturing due to their high sensitivity,
fast response times, and exceptional image quality.

One of the primary uses of CCDs in mobile assembly is for quality control and inspection. These
devices are used to capture high-resolution images of components and assemblies, allowing
manufacturers to detect defects, errors, and inconsistencies in real-time. CCDs can identify issues
such as misalignment, damage, and missing components, ensuring that only high-quality products
reach the market.

CCDs are also used for precise alignment and positioning of components during the assembly process.

R. I. T. Rajaramnagar 17
These devices provide accurate feedback on the position, orientation, and movement of components,
allowing for precise assembly and alignment. CCDs are commonly integrated into robotic systems
and automated assembly lines to ensure fast and accurate assembly of mobile devices. Additionally,
CCDs are used for optical character recognition (OCR) and barcode scanning in mobile assembly
processes. These devices can read text, serial numbers, and barcodes on components and assemblies,
ensuring traceability and quality control throughout the manufacturing process.

The importance of CCDs in mobile assembly cannot be overstated. Their high sensitivity, fast
response times, and exceptional image quality make them indispensable components for ensuring the
quality, reliability, and performance of mobile devices. By providing precise imaging and inspection
capabilities, CCDs help optimize production processes, minimize errors, and ensure the timely
delivery of high-quality mobile devices to consumers.

Fig. 14 CCD
3.3.6 Bar code scanner:
Bar code scanners are integral components in mobile assembly processes, offering efficiency,
accuracy, and traceability. These devices play a crucial role in various stages of mobile device
manufacturing, from inventory management to quality control and product tracking.

One of the primary uses of bar code scanners in mobile assembly is for inventory management and
component tracking. By scanning bar codes on incoming raw materials and components,
manufacturers can accurately track inventory levels, monitor stock levels, and ensure the availability
of materials for the assembly process. Bar code scanners help streamline inventory management,
reduce errors, and optimize supply chain operations.Bar code scanners are also used for quality control
and product traceability in mobile assembly processes. By scanning bar codes on individual
components and finished products, manufacturers can verify the authenticity of components, track the
assembly process, and ensure compliance with quality standards. Bar code scanners help identify and

R. I. T. Rajaramnagar 18
trace defective components, facilitate recalls, and ensure the quality and safety of mobile devices.
The importance of bar code scanners in mobile assembly processes cannot be overstated. Their ability
to accurately and efficiently capture data, track inventory, and ensure product quality makes them
indispensable tools for manufacturers. By providing real-time visibility into the assembly process, bar
code scanners help optimize production, minimize errors, and ensure the timely delivery of high-
quality mobile devices to consume

Fig. 15 Barcode Scanner

3.3.7 IPC:
Industrial personal computers (IPCs) are essential components in mobile assembly processes, offering
reliability, durability, and performance in demanding manufacturing environments. These specialized
computers are designed to withstand harsh conditions such as dust, moisture, vibration, and
temperature fluctuations, making them ideal for use in mobile device manufacturing facilities.

One of the primary uses of IPCs in mobile assembly is for process control and monitoring. These
computers are used to control and coordinate various aspects of the assembly process, including
component placement, soldering, testing, and quality control. IPCs provide real-time data and
feedback to operators, enabling them to monitor and adjust the assembly process for optimal
efficiency and quality.

IPCs are also used for data acquisition and analysis in mobile assembly processes. They collect and
analyse data from sensors, cameras, and other monitoring devices to identify trends, detect anomalies,

R. I. T. Rajaramnagar 19
and optimize production processes. IPCs provide valuable insights into the performance and reliability
of mobile devices, helping manufacturers improve product quality and reduce defects.

Another important application of IPCs in mobile assembly is for inventory management and
traceability. These computers track the movement and usage of components throughout the assembly
process, ensuring accurate inventory levels and providing traceability in case of product recalls or
quality issues. IPCs also integrate with enterprise resource planning (ERP) systems to streamline
production planning, scheduling, and reporting.

The importance of IPCs in mobile assembly processes cannot be overstated. Their reliability,
durability, and performance make them indispensable tools for controlling, monitoring, and
optimizing assembly processes in mobile device manufacturing facilities. By providing real-time data,
analysis, and control, IPCs help manufacturers improve efficiency, reduce costs, and ensure the high
quality and reliability of mobile devices.

3.3.8 Vision System:

Vision systems are indispensable tools in mobile assembly processes, offering precision, accuracy,
and efficiency. These systems utilize cameras and image processing algorithms to inspect, measure,
and guide components throughout the assembly process, ensuring high quality and reliability.
One of the primary uses of vision systems in mobile assembly is for quality control and inspection.
These systems are used to inspect components for defects, ensuring that only high-quality parts are
used in the assembly of mobile devices. Vision systems can detect imperfections such as scratches,
cracks, and misalignments with unparalleled accuracy, helping to maintain the highest standards of
product quality.

Vision systems are also used for component alignment and positioning during the assembly process.
By analysing images of components in real-time, these systems can ensure precise alignment and
placement, minimizing errors and improving assembly accuracy. Vision-guided robotic systems are
often used to automate assembly tasks, further enhancing efficiency and productivity.

Another important application of vision systems in mobile assembly is for process monitoring and
optimization. By continuously monitoring the assembly process, these systems can identify
inefficiencies, bottlenecks, and defects in real-time, allowing for rapid adjustments and
improvements.

R. I. T. Rajaramnagar 20
This helps manufacturers optimize their assembly processes, reduce waste, and improve overall
productivity. The importance of vision systems in mobile assembly cannot be overstated. Their ability
to inspect, measure, and guide components with precision and accuracy helps ensure the high quality,
reliability, and consistency of mobile devices. By detecting defects, guiding assembly tasks, and
optimizing production processes, vision systems play a critical role in the manufacturing of high-
quality mobile devices.

3.3.9 Motion Controller:

Motion controllers are essential components in mobile assembly processes, offering precise control,
flexibility, and efficiency. These controllers are used to regulate the movement of robotic arms,
conveyor belts, and other automated machinery, ensuring accurate and consistent assembly of mobile
devices.

One of the primary uses of motion controllers in mobile assembly is for controlling the movement of
robotic arms. These controllers provide the necessary instructions to robotic arms, allowing them to
pick up components, place them in the correct position, and perform assembly tasks with precision
and accuracy. By controlling the speed, trajectory, and orientation of robotic arms, motion controllers
help optimize the assembly process and ensure the quality and consistency of mobile devices.

Motion controllers are also used to regulate the speed and direction of conveyor belts and other
automated equipment in mobile assembly lines. They ensure smooth and efficient movement of
components along the assembly line, minimizing delays and optimizing production throughput. By
coordinating the movement of various components and machinery, motion controllers help streamline
the assembly process and maximize productivity. The importance of motion controllers in mobile
assembly cannot be overstated.

Their precise control, flexibility, and efficiency make them indispensable components for ensuring
the smooth operation of assembly lines, the precise assembly of components, and the quality control
of mobile devices. By providing accurate and consistent control of robotic arms, conveyor belts, and
other automated equipment, motion controllers help optimize production processes, minimize errors,
and ensure the timely delivery of high-quality mobile devices to consumers.

R. I. T. Rajaramnagar 21
3.4 Final Assembly:
In the final assembly stage of mobile production, several critical processes come together to assemble
the various components into a complete mobile device. Here is an overview of the typical processes
involved:

1. Housing Preparation: The process starts with the preparation of the device housing, which includes
cleaning, surface treatment, and any necessary modifications to accommodate internal components.
2. Motherboard Integration: The motherboard, or main circuit board, is installed into the housing. This
involves securing the motherboard in place and connecting it to other components such as the display
screen, battery, and camera modules.
3. Display Assembly: The display screen is carefully attached to the housing, ensuring proper
alignment and connection to the motherboard. This may involve the use of adhesives or mechanical
fasteners to secure the display in place.
4. Battery Installation: The battery is installed into the housing and connected to the motherboard.
This typically involves securing the battery in place and connecting it to the motherboard using a
connector or soldering.
5. Camera Module Integration: The camera modules are installed into the housing and connected to
the motherboard. This involves careful positioning and alignment to ensure proper functionality.
6. Button and Port Installation: Physical buttons, such as power and volume buttons, as well as ports
such as USB and headphone jacks, are installed into the housing and connected to the motherboard.
7. Final Inspection: Once all components are installed, the device undergoes a final inspection to
ensure that everything is properly assembled and functioning correctly. This may include functional
testing, cosmetic inspection, and software verification.
8. Packaging: Once the device has passed final inspection, it is packaged and prepared for shipment
to distributors or retailers. This involves applying labels, inserting user manuals and accessories, and
sealing the packaging for transport.

Throughout the final assembly process, special purpose machines (SPM) are used to streamline
production and ensure consistency and quality. These machines may include robotic assembly
systems, automated screwdrivers, and testing equipment to verify the functionality of the finished
device. Overall, the final assembly stage is a critical step in mobile production, where all the
individual components come together to create a finished, functional device ready for sale to
consumers.

R. I. T. Rajaramnagar 22
3.5 Testing and Quality assurance:
Testing, quality assurance, and quality control are critical aspects of mobile production, ensuring that
every device meets the highest standards of performance, reliability, and safety before reaching the
hands of consumers.
1. Functional Testing:
- Functional testing verifies that all components of the mobile device are functioning correctly. This
includes testing features such as touchscreen responsiveness, camera functionality, audio output, and
connectivity (Wi-Fi, Bluetooth, cellular).
- Software testing ensures that the operating system and installed applications function as intended,
without any glitches or errors.
2. Performance Testing:
- Performance testing evaluates the speed, responsiveness, and overall performance of the mobile
device. This includes testing processor speed, memory performance, and battery life under various
usage scenarios.
- Performance testing also ensures that the device can handle multitasking, gaming, multimedia
playback, and other intensive tasks without slowdowns or crashes.
3. Durability Testing:
- Durability testing assesses the mobile device's ability to withstand various environmental factors
and usage conditions. This includes testing for resistance to drops, shocks, vibrations, and temperature
extremes.Water and dust resistance testing ensures that the device can withstand exposure to water,
moisture, and dust without damage.
4. Connectivity Testing:
- Connectivity testing verifies that the mobile device can establish and maintain reliable connections
to cellular networks, Wi-Fi networks, and other devices.
- Bluetooth and NFC testing ensures that wireless connectivity features are functioning correctly
and can communicate with other devices.
5. Quality Assurance:
- Quality assurance involves continuous monitoring and improvement of the mobile production
process to ensure consistent quality and reliability.
- Quality assurance measures may include regular audits, process improvements, and training
programs to ensure that all employees adhere to quality standards and best practices.
Testing, quality assurance, and quality control are integral parts of the mobile production process,
ensuring that every device meets the highest standards of performance, reliability, and safety. By
conducting rigorous testing and implementing quality assurance measures, mobile manufacturers can
deliver high-quality products that meet the expectations of consumers.

R. I. T. Rajaramnagar 23
 Chapter 4
Special Purpose Machines

4.1 Special purpose machines (SPM):

Special Purpose Machines (SPM) play a critical role in mobile production, contributing to
efficiency, precision, and quality throughout the assembly process. These specialized machines are
designed to perform specific tasks with high accuracy and repeatability, making them
indispensable in modern mobile manufacturing facilities.

1. Component Manufacturing: SPMs are used in the production of various mobile components
such as circuit boards, display screens, and casings. For instance, CNC machines are used for
precise cutting and shaping of components, while injection molding machines are used for
manufacturing plastic parts.

2. Component Integration: SPMs are employed to assemble individual components into sub-
assemblies. Robotic arms equipped with vision systems are used for precise placement of
components, while soldering machines ensure secure connections. Adhesive application machines
are also used to bond components together accurately.

3. Final Assembly: In the final assembly phase, SPMs are used to integrate sub-assemblies and
components into the complete mobile device. Automated assembly lines, equipped with conveyor
systems and robotic arms, streamline the assembly process. Specialized machines such as pick-
and-place systems ensure accurate placement of components, while automated screw tightening
machines ensure proper fastening.

4. Testing and Quality Assurance: SPM are used extensively for testing and quality assurance
purposes. Automated test benches conduct functional tests, performance tests, and durability tests
on each mobile device to ensure it meets the required standards. Vision inspection systems detect
defects and inconsistencies in components and assemblies, ensuring product quality and reliability.
- In summary, SPMs are integral to every stage of mobile production, from component
manufacturing to final assembly and testing. By automating repetitive tasks, minimizing errors,
and ensuring precision, SPMs help manufacturers achieve high levels of efficiency, productivity,
and quality in mobile device manufacturing.

R. I. T. Rajaramnagar 24
4.2 Working principle of SPM in mobile assembly:

Special Purpose Machines (SPM) play a vital role in mobile assembly processes, optimizing
efficiency, precision, and productivity. The working principle of SPM in mobile assembly involves
several key steps:

1. Task Analysis:

Before designing an SPM, a thorough analysis of the assembly process is conducted to identify
the tasks that can be automated or optimized.

2. Design and Engineering:

Based on the task analysis, engineers design specialized machines tailored to perform specific
assembly tasks.

The design process involves selecting the appropriate components, mechanisms, and control
systems to ensure efficient and precise operation.

3. Automation and Control:

SPMs are equipped with sensors, actuators, and control systems to automate the assembly
process.

Sensors detect the position, orientation, and quality of components, providing feedback to the
control system.

The control system uses this feedback to adjust the machine's operation, ensuring accurate and
consistent assembly.

4. Integration with Assembly Line:

SPMs are integrated into the assembly line, either as standalone machines or as part of a larger
automated system. They are synchronized with other machines and processes to ensure smooth
and efficient operation.

5. Operation and Monitoring:

Once integrated, SPMs are operated and monitored by trained personnel.Operators monitor the
machine's performance, make adjustments as necessary, and troubleshoot any issues that arise.

6. Maintenance and Optimization: Regular maintenance is performed to ensure the SPM operates

R. I. T. Rajaramnagar 25
at peak efficiency. Continuous optimization is done to improve performance, increase throughput,
and reduce downtime.

Overall, the working principle of SPM in mobile assembly involves the design, automation,
integration, and optimization of specialized machines tailored to perform specific assembly tasks
with precision and efficiency. These machines play a crucial role in streamlining the assembly
process, ensuring product quality, and increasing productivity in mobile device manufacturing.

4.3 Types of SPM used in mobile assembly process:

There are several types of Special Purpose Machines (SPM) used in mobile assembly processes,
each designed to perform specific tasks with precision and efficiency:

1. Pick-and-Place Machines: These machines are used to precisely position and solder surface-
mount components onto printed circuit boards (PCBs). Equipped with advanced vision systems
and robotic arms, pick-and-place machines identify component locations and place them onto the
PCB with micron-level precision.

2. Automated Assembly Lines: Automated assembly lines are integral to modern mobile
manufacturing facilities, enabling high-volume production with minimal human intervention.
These assembly lines integrate a variety of specialized machines, including conveyor systems,
robotic arms, and automated testing stations, to streamline the assembly process and maximize
efficiency.

3. Testing Equipment: Testing equipment such as automated test benches and quality control
stations are essential for ensuring that each mobile device meets the required performance and
quality standards. These machines conduct comprehensive tests on every aspect of the device,
including functionality, connectivity, and durability, to identify any defects or deficiencies that
may impact the user experience.

4. Robotic Assembly Systems: Robotic assembly systems are used for precise and efficient
assembly of mobile device components. These systems use robotic arms equipped with grippers,
suction cups, and other specialized tools to pick, place, and assemble components with high
accuracy and repeatability.

5. Laser Marking Machines: Laser marking machines are used to engrave serial numbers, logos,
and other identification marks onto mobile device components. These machines offer high
precision and speed, allowing manufacturers to mark components with permanent, high-quality
markings.

R. I. T. Rajaramnagar 26
These are just a few types of Special Purpose Machines (SPM) used in mobile assembly processes.
Each machine plays a critical role in optimizing production throughput, ensuring product quality,
and minimizing errors in the assembly of mobile devices.

4.4 Importance of SPM in mobile assembly:

Special Purpose Machines (SPM) play a critical role in mobile assembly processes, offering several
key advantages that are essential for efficient and reliable manufacturing.

One of the primary advantages of using SPM in mobile assembly is their ability to automate
repetitive tasks with unparalleled precision and efficiency. These machines are specifically
designed and tailored to perform particular tasks, such as component placement, soldering, and
testing, with high levels of accuracy and consistency. By automating these tasks, SPMs help
manufacturers increase productivity, reduce cycle times, and minimize errors, leading to cost
savings and improved competitiveness in the mobile device market.

Additionally, SPMs significantly reduce manual intervention and human error in the assembly
process, leading to improved product quality and consistency. By ensuring precise and accurate
assembly, SPMs help meet the stringent standards of performance, durability, and safety expected
by consumers. This not only enhances the reliability and performance of mobile devices but also
reduces the risk of defects and product recalls, protecting the reputation and brand image of
manufacturers.

Furthermore, SPMs enhance flexibility and adaptability in mobile assembly processes. They can
be easily reconfigured or customized to accommodate changes in product design or manufacturing
requirements, allowing manufacturers to respond quickly to market demands. This flexibility
enables manufacturers to introduce new products more efficiently and cost-effectively, giving them
a competitive edge in the fast-paced mobile device market

Overall, the importance of SPMs in mobile assembly cannot be overstated. These machines play a
crucial role in optimizing production processes, improving product quality and consistency, and
enhancing the competitiveness of manufacturers in the mobile device market. By automating
repetitive tasks, minimizing errors, and enhancing flexibility, SPMs help manufacturers meet the
growing demand for high-quality, innovative mobile devices while remaining cost-effective and
competitive in an increasingly dynamic industry.

R. I. T. Rajaramnagar 27
Chapter 5

Maintenance Work

During the internship various machine downs attended, below are the some down attended and the
solutions given to it. Machine downtime issue involving the RCAM machine (rear camera machine)
used in the production line of mobile assembly. This machine is responsible for assembling the rear
camera onto mobile phones, a crucial step in the manufacturing process.

The machine downtime involved several issues, the first being an error in the CCD (charge-coupled
device). The CCD is integral to the RCAM machine's operation as it captures images during the
camera assembly process. Specifically, it takes photos while placing and screwing the camera onto
the mobile. The process is managed using Cognex Plus Assembly Software and Vision Pro Software,
which continuously monitor the images captured by the CCD. These systems follow pre-fed
instructions to ensure precise assembly. For instance, they check the fixed distance between the
camera module and the flex of the camera module. If this distance is abnormal, the system detects the
issue before the camera module is placed in the mobile. Additionally, the software checks the holes
on the mobile for any foreign particles that could interfere with the assembly process.

The second issue involved a malfunction in the pneumatic carrier cylinder. This cylinder plays a vital
role in locking and unlocking the mobile on the conveyor belt, ensuring that the mobile remains in
place during the camera module placement. This is crucial to prevent displacement and potential
damage to the mobile phone. The mobile is supported by a structure called a pallet, which secures the
device from the moment it enters the machine until it exits. The pallet system ensures that the mobile
is correctly positioned and stable throughout the assembly process.

Addressing these issues was essential to resume the smooth operation of the RCAM machine and
maintain the efficiency and quality of the mobile assembly line. By resolving the CCD error and the
pneumatic carrier cylinder malfunction, the production line could continue to produce mobile phones
with properly assembled rear cameras, ensuring product integrity and performance.

Another issue encountered involved the main software that controls all other software systems, which
was indicating that the sensors were disabled. Unusually, it showed both "on" and "off" options
simultaneously. Upon investigation, I discovered that the address of the I/O Module extension had
R. I. T. Rajaramnagar 28
changed, causing the problem. By resetting the address of the I/O Module to its default settings, the
sensors began functioning correctly again. This adjustment was crucial as the sensors are integral to
the precise operation of the RCAM machine, ensuring that all components are accurately positioned
and correctly assembled. Restoring the I/O Module's address resolved the sensor issue, thereby
restoring normal operational functionality and preventing potential disruptions in the mobile assembly
process. This quick resolution helped maintain the production line's efficiency and ensured the
continued quality of the assembled mobile devices.

One of the problems was reed switch problem, while tackling issues with a Reed sensor requires a
systematic approach to troubleshooting and resolving potential problems. The first step involves
manually operating the sensor to assess its functionality. By physically interacting with the sensor,
one can determine if it is responsive and properly detecting changes in its magnetic field. This hands-
on approach allows for immediate feedback on the sensor's performance.

Following manual operation, the focus shifts to troubleshooting the electrical wiring. This stage is
critical in ensuring that the sensor is receiving and transmitting signals accurately. Starting with the
connection at the hub, attention is then directed towards verifying the integrity of the connection to
the I/O module. Finally, checking the connection at the Google Tech Motion Controller ensures that
the entire wiring system is thoroughly examined for any faults or inconsistencies.

If the issue persists despite these efforts, replacing the sensor with a functional stepper motor becomes
the next course of action. This replacement process involves several steps aimed at identifying and
rectifying the underlying problem. Firstly, manually moving the stepper motor allows for a direct
assessment of its functionality. Any irregularities or inconsistencies in movement can be noted for
further investigation.

Next, a thorough inspection is conducted to identify any obstructions or jams that may be hindering
the motor's operation. If necessary, readjusting or reinstalling the screws ensures proper alignment
and smooth movement. However, if the issue persists despite these measures, replacing the stepper
motor entirely with a functional one becomes necessary. Retesting the operation of the new motor is
crucial to ensure that the problem is effectively resolved.

In summary, addressing issues with a Reed sensor and stepper motor involves a systematic approach
that includes manual operation, thorough wiring troubleshooting, and potential replacement if

R. I. T. Rajaramnagar 29
necessary. This methodical process ensures that any problems are identified and resolved effectively
to maintain the functionality of the system.

Scanner calibration issues often stem from problems with the CCD sensors, which can result in
misaligned images or inaccurate colors. To address these problems, start by reviewing and adjusting
the scanner's calibration settings. This involves configuring the color profile, brightness, contrast,
resolution, and gamma to ensure they are set correctly. It's essential to fine-tune these settings as they
directly impact the quality of the scanned images.

After adjusting the software settings, move on to inspect the hardware, particularly the CCD sensor.
Dust or dirt on the sensor can cause significant image quality issues. Gently clean the sensor with a
soft cloth, being careful not to scratch or damage it. Examine the sensor for any physical damage, as
a damaged CCD sensor will need to be replaced.

By thoroughly checking both the software calibration settings and the physical condition of the CCD
sensor, you can resolve most calibration issues, ensuring your scanner produces clear, accurate
images.

CPP Machine related issues and troubleshooting:

1. Drive over current- It means that two cover plates are placed on single pallet. Then firstly
clear alarm then removes pallet and cover plate which is stuck on top and bottom vacuum cups
and then done homing of machine. After homing of machine then place pallet with cover plate
and then once again and taken trial to ensure proper working.

2. Barcode Scanning failed – The barcode scanner is placed at station 1 to scanning the barcode
placed on pallet to record the serial numbers of cyclones. The problems are improper position
of the QRs printed on pallet the appropriate action is that first adjust the barcode scanner then
restart the barcode scanners images and adjust the live image in software to set standard image
of barcode.

3. Insufficient Air pressure- The air pressure(Vaccum) are required to hold the cover plate,
pallet and cyclones. The air pressure is requires to maintain the proper working of machine

R. I. T. Rajaramnagar 30
 Firstly check the air pressure connection to machine from the air pressure line then check the
pressure value at pressure regulator and FRL unit check the sufficient pressure value and check
the air pressure hoses and vaccum cups to ensure that it does not have any leakage.

4. Reference image Setting-The Vision System monitors each image of cyclone and its pins and
mainly Cognex software is used to comparing the reference image with Standard image, The
CPP machine have 5 CCD (Charged Couple Device). Start the Cognex software then select
the CCD1 to CCD 3 for capturing the images of the Cyclone its checks whether the cyclone
is placed well of not Then CCD4 a Bottom.
Placed CCD for capturing the bottom images of pin of cyclone. CCD5 is for reinspection
station for checking the the alignment of cyclone, cyclone pins, and the pallet. Firstly start the
Cognex software then select the number of CCD then open the standard image and set the
reference image as per standard image for assembly station vision system then Bottom CCD
is to set to take image for pins. Reinspection CCD is captures the images in that we checks
proper alignment of pins with cyclone.

5. Cyclone tray stucking issues- The Cyclone tray is loaded from loading side that side while
tray coming upwards that time chances of tray stuckes in the loading assembly.
We countered that issue that the stepper motor is used in it that we followed preventive
maintainance and while jacking the cyclone tray is Unevenly jacked that time we made proper
jacking of cylinders uniformly.
Unloading tray is going down after unloading of cyclones while going down the that tilts that
time we adjusted the down conveyor and taken trial run for proper running of machine.

6. Tossing of Cyclone- the tossing means machine shows not good part the tossing is mainly
occurred in the assembly station in that it has mainly reasons like bending of cyclone pins
bend in cyclone, absence of hot bonding glue on that time we tried to make proper alignment
of the cyclone I cyclone tray and maintain the proper air pressure for picking the cyclone and
proper placing on the pallet.

7. Replacement of sensors- The proximity sensor is used in the station 1 for identify whether
the cyclone pallet is their or not that time the proximity sensor is downside of

R. I. T. Rajaramnagar 31
 Stopping cylinder as per commands that remove the screws first then remove the cylinder then
sensor have some locking removed carefully then replaced the sensor and repeated same
procedure and then taken trial on station 1

Material Tossing Error Troubleshoot:

This issue occurred on Cyclone Pick and Place (CPP) Machine in Component Sub-Assembly –
Multi Layer Board (CSA-MLB) Line. This error occurred to the tolerance for the LB material is kept
between ±1º. But during final inspection, the angle value exceeded the tolerance limit by ±2.5º. This
issue was solved by setting the offset value for the pick and place robot and the offset value was set
for Charge Coupled Device (CCD).

Motion Controller Error Troubleshoot:

This issue occurred because during shift change of employees, the operator accidentally turned off
the machine. Because of the sudden shutting down of the machine, the voltage value which must be
24V, exceeded for linear servo used in Pick and Place Gantry. This issue was solved by restarting the
software and changing the config file.

Material Pick-up Error Troubleshoot:

This issue occurred on Cyclone Pick and Place (CPP) Machine in Component Sub-Assembly – Multi
Layer Board (CSA-MLB) Line. In this issue the material which is to be picked up that is Cyclone
which is nothing but an induction coil which is used for Wireless Charging in the mobile phone. This
coil is supposed to be picked by nozzles on the Gantry. This issue was such that the nozzle was picking
the Cyclones up from the pick-up tray and while moving towards the placing point, the cyclone were
being dropped in midway. For this error, I along with my senior inspected the whole scenario then
tried to overcome this situation firstly by cleaning the face of the nozzles. This didn’t help then we
tried working on its vacuum parameters. We had to slightly change the values for its vacuum
parameters then we adjusted the valves. In this way we made few changes in both the software and
hardware of the machine to overcome this issue. After the troubleshooting of this issue, we had to
observe the machine for the process to be continued without any errors for the next 10 pallets.

R. I. T. Rajaramnagar 32
Head Alignment Issue Troubleshoot:

This issue occurred on Cyclone Hot Bar (CHBS) Machine in Component Sub-Assembly – Multi-
Layer Board (CSA-MLB) Line. In this issue the error was that the head which descends downwards
for the hot bonding process of Cyclone which is an induction coil which is used for Wireless Charging
in the mobile phone. In this process of hot bonding, the cyclone comes under the Hot Bonding Heads
which descend downwards to put an air pressure with a certain temperature for bonding the cyclone
nodes with the Multi-Layer Board (MLB) by melting of the flux to shield the connection. In this error,
the head which is supposed to descend for a certain distance, was descending beyond its limit. This
resulted into the tossing and eventually Not Good (NG) state of the cyclones. Due to exceeding of the
head path, the flux didn’t get to its place as the head was getting closer to the pallet than its specified
distance. Thus to overcome this error, we had to get the Standard Operating Procedure (SOP)
document from the AE Team and go through the document to get to know about the procedure to set
the path for the head and what are its pre-determined values to descend till a suitable distance from
the pallet in order to carry out the hot bonding process without tossing or NG. Then we changed the
parameters for the path of the head. Then we had to restart the software and change the config file.
Then we had to observe the process for the next 20 pallets to come out from the machine without
flashing any kind of error.

Photoelectric Sensor Issue Troubleshooting:

Cyclone Pick and Place (CPP) machine was constantly humming for an alarm of Tray-Out Drawer
Full. This alarm generally occurs when the drawer which is at the rear side of the machine that is used
to take out the trays that previously carried Cyclone coils after they are empty after taking out the
Cyclones from the trays. In the CPP machine, the empty trays are stacked in a drawer. When the
height of the stacked trays reaches in the range of the sensor, it signals an alarm for as Tray-Out
Drawer Full. After this alarm, the operator has to open the drawer and take the empty trays out. The
issue was such that even after taking the trays out, the alarm was still going to sound after 2-3 seconds.
We observed the machine and realized that even though the drawer was empty, the error was still
popping. Thus we checked the sensor and it turned out to be in Not Good (NG) state. Then we checked
the sensor serial number and noted it down in order to borrow a spare sensor of a same kind. There is
a spare room for Vendors at some of the shopfloors which is used to store the spares of each kind for
every machine of a vendor. There, at the spare room the spare needs to be mentioned in the log book,
and then it has to be taken out. After acquiring the spare from Spare Room, we went to shopfloor and

R. I. T. Rajaramnagar 33
changed that particular sensor. After changing the sensor, we had to open the drawer and check the
sensor after every hour in order to check whether the sensor is working or not or if it has been
dislocated from its actual position.

Ringer Switch Tossing Issue:

This issue occurred on Ringer Switch Welding (RSW) Machine in Component Sub-Assembly –
Multi-Layer Board (CSA-MLB) Line. In this machine, the ringer switch of an iPhone is welded with
Multi-Layer Board (MLB). This welding takes place by checking the position of Ringer Switch placed
on Multi-Layer Board (MLB) through Charge Coupled Device (CCD). After checking the position,
the welding is done. Issue with this machine was such that the welding was done on the slightly to the
left of the desired point. This was due to the unclear visuals were obtained from Charge Coupled
Device (CCD) and the position of the CCD was moved towards left and thus as a result of this, the
welding spot was also moved towards the left from its actual location. In order to overcome this issue,
we had to change the position of CCD from its then position to the desired position. Along with this,
to overcome the issue of blurred visuals, we had to clean the lens with Isopropyl Alcohol; that is IP
Liquid. After the cleaning of lens, the blurred vision issue was solved but still, there was still the issue
with the welding point tossing. For this, we had to change the offsets and restart the software. After
that we changed the config file and started the software. After this procedure, the pallets were fed to
the machine for welding and we had to observe the obtained pallets after the process. We had to
examine at least 15 pallets containing 16 units per pallet.

Downtime root causes and its corrective actions:

Product re-inspection NG
Abnormal print head distance and angle

Print nozzle distance debugging

1. Placed the carrier equipped with profiling into the entrance of the assembly line, clicked [S3
one-key pick-up] on the software operation interface, and the carrier flowed automatically.
2. Entered S3 station and positioned.
3. In the software operation interface, checked the X-axis of the pipeline and the Y-axis servo
enable of the inkjet module.

R. I. T. Rajaramnagar 34
 4. Manually pushed the transfer platform, moved the front cover of the vehicle to the bottom of
the inkjet module, moved the Z axis of the inkjet module in the movement area of the inkjet
module, and moved the nozzle trolley to 1mm above the front cover of the vehicle. Then
selected the moving distance [short distance 0.1mm/times], lowered and moved the nozzle
trolley to 0.1mm above the front cover of the vehicle.

Adjustment of nozzle angle:

1. First determined the input direction of the adjustment material. The position of the top cover camera
was located in the direction of the arrow pointing of the vehicle. Put the adjustment material on the
carrier, then stuck the PSF film to the printing surface of the adjustment material, and then put the
carrier into the entrance of the assembly line.
2. Opened the RIP software on the desktop. In the RIP program, selected [Debug Parameters], set the
distance to the electric eye to 50, and clicked [Refresh], confirmed that the parameters had been saved.
3. In the printer program, selected [Debug Parameters], then selected [Skew Calibration], closed the
function box on the right, clicked Print (Figure 3), and the upper left corner of the software interface
displayed “Print.”
4. In the software operation interface, selected [Manual Page], then selected [Print Page] and clicked
[Inkjet Test]. The carrier automatically flowed into the inkjet station, positioned, and printed.
5. Observed the printing effect; the printed adjacent lines were relatively horizontal and there was no
overlap.
6. If the print nozzle angle was abnormal, first loosened the nozzle angle fixing screw, adjusted the
nozzle angle and adjusted the top wire, used the inner six. Closed all the safety doors to ensure that
the device was initialized under safe conditions. Turned the top screw clockwise with the angle
wrench, and L3 approached L2, and vice versa, so that the printed L3 was in the middle of L1 & L2,
and aligned the level, then tightened the nozzle angle fixing screw.

Bad printing NG:

Ink break: There are white lines on the printed text, logo or barcode, lack of ink, or broken lines on
the color scale card.

1. Opened the software operation interface, in the point control area, moved the nozzle to the cleaning
position, above the moisturizing plate, with ink pressing steps.
2. After putting on the plastic gloves, folded the clean dust-free cloth, dipped it in the cleaning
solution, and wiped it from the middle of the nozzle to the outside.
R. I. T. Rajaramnagar 35
3. Wiped the bottom once, and then wiped from the middle of the nozzle to the bottom once.
4. Triggered the ink pressing button on the trolley mechanism, manually pressed the ink for 3 seconds,
and then wiped the surface of the nozzle with a clean dust-free cloth.
5. After the cleaning was completed, printed 3 pieces of color gradation, conducted a color gradation
test, and judged the status of the nozzle.
6. If there was no abnormality in the color scale, the equipment could be used for normal production
The servo motor or driver is abnormal
Drive alarm: Loose or damaged components, lines and other mechanisms purchased in the market
1. Replaced or reconnected the motor driver cable, power cable, and encoder cable.
2. Replaced the motor or driver.

Error 6019
This issue occurs because of the buffer file is not compiling because of the file is corrupted and the
config file is not properly compiled due to the software and the HMI interface. This issue was solved
by uploading the new config file and rebooting the software.

Gantry homing error

This issue occurs during the LINE BRING UP of the CPP machine. The error was that the gantry was
not moving towards the homing position and was getting stopped in the middle. This issue occurred
because the driver was not providing enough current towards the motor of the X and Y axis. This
issue was solved by rebooting the driver and controller. After which the position points were again
teached and then the reference points were given and thus the issue was resolved.

CCD capture issue

One primary cause is inadequate lighting conditions, which can result in poor image quality or
complete failure to capture images. Additionally, dust or debris on the CCD sensor or lens can obstruct
the sensor's ability to accurately record images, leading to defects or distortions. Electrical
interference or noise in the system can also disrupt the signal from the CCD, resulting in corrupted
data. Furthermore, software or firmware glitches in the camera or related processing hardware might
prevent proper image acquisition. Finally, physical damage to the CCD sensor itself, whether due to
mishandling or exposure to harsh environments, can impair its functionality and lead to capture issues.
Regular maintenance and calibration, along with ensuring optimal operating conditions, are essential
to mitigate these problems.

R. I. T. Rajaramnagar 36
Barcode scan issue
One common cause is poor quality or damaged barcodes, which can result from printing errors,
physical damage, or dirt and smudges on the barcode surface. Environmental factors such as
inadequate lighting or glare can also interfere with the scanner's ability to accurately read the barcode.
Misalignment between the scanner and the barcode, or the barcode moving too quickly through the
scanning area, can further complicate the process. Additionally, software-related issues, such as
outdated drivers or misconfigured settings, can hinder the scanner's performance. Regular
maintenance, ensuring proper alignment, and keeping the barcode surface clean are crucial steps to
mitigate these issues and ensure efficient and accurate barcode scanning.

Flux dispensing issue

The dispense issue in the FLUX machine is primarily attributed to a malfunction in the delivery
system. This malfunction can be caused by various factors, including clogs in the dispensing nozzles,
irregularities in the fluid pressure, or wear and tear of the mechanical components. Additionally,
improper calibration of the dispensing mechanism can lead to inconsistent flow rates, affecting the
accuracy and precision of the dispensed material. External factors, such as contamination or incorrect
viscosity of the material being dispensed, can further exacerbate the problem. Regular maintenance,
thorough cleaning, and periodic calibration are essential to prevent such issues and ensure the smooth
operation of the FLUX machine.

Robot position issue

Robot calibration issues in machines can significantly affect the accuracy and efficiency of automated
operations. Calibration involves setting up the robot to accurately interpret its coordinates and
movements within its working environment. When calibration is off, several problems can arise.
Inaccurate positioning may occur, causing the robot to miss intended locations and leading to errors
in tasks such as assembly, welding, or material handling. This misalignment can result from incorrect
initial setup or gradual shifts due to mechanical wear. Operational inconsistency can also be a
problem, as a poorly calibrated robot may perform the same task differently each time, causing
inconsistencies in product quality and increasing the likelihood of defects. Additionally, misalignment
forces the robot to operate under suboptimal conditions, potentially increasing mechanical stress on
components and accelerating wear and tear. Calibration issues can also lead to incorrect data from
sensors, causing the robot to misjudge distances, angles, or positions, which can result in collisions
or incomplete tasks. Frequent recalibration or troubleshooting due to calibration errors can lead to
increased downtime, affecting overall productivity. Furthermore, inaccurate movements can pose

R. I. T. Rajaramnagar 37
safety risks to human operators working alongside robots, increasing the likelihood of accidents or
injuries. Addressing calibration issues involves ensuring precise setup during installation, regular
maintenance checks, and recalibration as needed. Implementing robust calibration procedures and
utilizing advanced calibration tools can help maintain optimal robot performance and accuracy.

Conveyor issue
Conveyor issues in machines can disrupt the flow of operations, leading to inefficiencies and
downtime. Common problems include misalignment, where the conveyor belt deviates from its path,
causing items to fall off or jam the system. This misalignment can result from wear and tear on the
belt or improper installation. Additionally, conveyor belts can suffer from uneven tension, leading to
slippage or excessive strain on certain areas, which can cause premature belt failure. Mechanical
failures, such as broken motors or faulty bearings, can halt the conveyor entirely, while issues with
the control system, like software glitches or sensor malfunctions, can lead to erratic conveyor speeds
or stopping. Accumulation of debris and lack of regular maintenance can also cause blockages and
reduce the efficiency of the conveyor system. To mitigate these issues, it is essential to ensure proper
installation, conduct regular maintenance and inspections, and promptly address any mechanical or
control system problems. Employing high-quality components and keeping the conveyor clean can
further enhance its reliability and performance.

Material Tossing Error Troubleshoot.

This issue occurred on Cyclone Pick and Place (CPP) Machine in Component Sub- Assembly-Multi
Layer Board (CSA MLB) Line. This error occurred to the tolerance for the LB material is kept
between +/-1. But during final inspection, the angle value exceeded the tolerance limit by 2.5°. This
issue was solved by setting the offset value for the pick and place robot and the offset value was set
for Charge Coupled Device (CCD)

Motion Controller Error Troubleshoot

This issue occurred because during shift change of employees, the operator accidentally tuned off the
machine. Because of the sudden shutting down of the machine, the voltage value which must be 24V,
extended for linear servo vowed us Pick and Place Gantry. This issue was solved by restarting the
software and changing the config file.

Material Pick-up Error Troubleshoot

This issue occurred un Cyclone Pick and Place (CPP) Machine in Component Sub- Assembly- Multi

R. I. T. Rajaramnagar 38
Layer Board (CS/ (CSA-MLB) Lime In this issue the material which is to be picked up that in Cyclone
which a nothing but an induction cod which is used for Wireless Charging in the mobile phone. This
coil is supposed to be picked by nozzles on the Gantry This issue was such that the nozzle was picking
the Cyclone up from the pick-up tray and while moving towards the placing point, the cyclone were
being dropped in midway. For this error, I along with my senior inspected the whole scenario then
tried to overcome this situation by changing the face of the nozzles. This didn't help than we tried
working on its vacuum parameters. We had to slightly change the values for its on its vacuum
parameters then we adjusted the valves. In this way we made few changes in both the software and
hardware of the machine to overcome this issue. After the troubleshooting of this issue, we had to
observe the machine for the process to be continued without any errors for the next 10 pallets.

Head Alignment Issue Troubleshoot:

This issue on cyclone Hot Bar (CHBS) Machine in Component Sub- Assembly-Multi-Layer Board
(CSA MLB) Line. In this issue the error was that the head which descends downwards for the hot bon
ding process of Cyclone which is an induction col which is used for Wireless Charging in the mobile
phone. In the process of hot bonding, the cyclone comes under the Hot Bonding Heads which descend
downwards to put on pressure with a certain temperature for bonding the cyclone nodes with the
Multi-Layer Board (MLB) by melting of the flux to shield the connection. In this error, the head which
is supposed to descend for a e a certain distance, was descending beyond d its limit. This resulted its
into the tossing and eventually Not Good (NG) state of the cyclones.

Motion Controller Error

Motion controller issue occurs due to the communication error between the Motors, Drivers because
this communication is done by ethernet communication protocol this error because of heavy current
fluctuation and because of the encoder battery gets overcharged. This issue is solved by rebooting the
SPII PLUS SOFTWARE and re-establishing the connection securely using the voltmeter and the
connection SOP.

DP Machine related issues and troubleshooting:

HMI Not Connected/Not Working

HMI was showing a blank screen all the time. HMI = the link between the Machine & the operator.
Shows crucial data like connection of components (Robot, CCD, Scanners etc.), live images of the
CCD, stopping cylinders' positions, number of units passed, their codes, & all required data of every

R. I. T. Rajaramnagar 39
unit passing through it.

Troubleshooting:
- Checked HMI screen lights to ensure power.
- Checked data cable hub by connecting to another HMI screen.
- Found the problem in the HMI screen itself.
- Replaced the HMI screen, and it worked fine.

CCD Connection Speed Not Good

CCD operating at 100MBPS instead of normal 1GBPS. CCD = captures images of
housing/components to ensure accuracy, compares with reference images to spot errors, saves images,
& can be viewed live on HMI screen.

Troubleshooting:
- Ensured CCD connections were good.
- Checked data & power cables for damage.
- Checked CCD IP address.
- Found problem in the data cable.
- Replaced the data cable, and CCD worked fine at 1GBPS.

QR Code Scanner Disconnecting

QR Code Scanner = scans QR of housing for all related data (tasks performed, stations visited, etc.),
crucial for identification & processing, sends data to customer who sends a specific code back, &
gives previous code if unit returns.

Troubleshooting:
- Checked & reconnected scanner cables.
- Scanner worked fine initially but disconnected again.
- Changed the QR code scanner cable after monitoring.

R. I. T. Rajaramnagar 40
Shim Tossing Issue
Shim not picked properly by jaws. Shim = internal part of mobile phone buttons (Power, Volume
up/down buttons), sizes range 0.35mm to 0.56mm. Jaws = mechanical component that picks shim
from loader & moves to robot pickup position, operated by pneumatic cylinders, moves up-down &
in-out.

Troubleshooting:
- Monitored machine process.
- Found jaw position disturbed.
- Adjusted jaws up-down & in-out.
- Operated machine manually to test.
- Adjusted jaws until desired position was found.

R. I. T. Rajaramnagar 41
 Chapter 6
Conclusion
•

• Mobile device assembly is a complex process involving multiple crucial stages, from
component manufacturing to final assembly, requiring precise attention to detail.
• Specialized machines, such as pick-and-place machines, automated assembly lines, and
testing equipment, optimize production throughput and ensure product quality.
• Training on "Different Phases of Mobile Assembly and Special Purpose Machines" provided
valuable insights into the intricacies of mobile technology and assembly processes.
• Continuous advancements in Special Purpose Machines (SPMs), including AI, machine
learning, and human-robot collaboration, enhance efficiency, quality, and agility in mobile
device manufacturing.
• Systematic approaches to addressing machine downtime challenges in Component Sub-
Assembly lines ensure operational continuity and production efficiency.

R. I. T. Rajaramnagar 42