Gen7 Gen8 Gen9 GenX

The Gen 7 speaker production line from Phase Automation is a complete, turn key assembly system that allows your facility to process conventional drivers from raw parts to completed drivers, tested and ready to go in approximately 2 and a half hours complete process time without using exotic or expensive adhesives. Gen 7 is designed to process 2" to 8" drivers at high speed in a single sided line- one process flow coupled with a dual level curing system. Gen 7 was developed primarily for facilities located in low labor cost areas who still need precision controls and efficiency. Due to the advanced curing system, Gen 7 systems deliver fantastically repeatable drivers, year after year and make your process practically immune to the seasonal climate

variations that have such a drastic impact on adhesives and overall speaker performance.

Gen 7 is comprised of several sections, starting with the Motor assembly section. This section includes a staking press integrated with adhesive processing for front plates, a motor assembly workstation supported with Phase Automation's Pro 1385-Plus adhesive dispense platforms at the gluing stations. Gen 7 also includes a segmented pallet delay section which is connected to your ventilation system to enhance the workplace environment. Motors are completed in approximately 15 minutes, start to finish when used with typical acrylics and epoxies.

The driver assembly process is divided into three stages with the first two stages leading into a high capacity automated curing system. Single bead adhesive stations are supported by Pro 1385-Plus series adhesive machines and dual bead stations are supported by Pro 2385-Plus adhesive machines. The Pro 1385 and Pro 2385 machines are turntable based, high speed adhesive dispense platforms capable of cycle times of under 4 seconds while still maintaining 2+ Cpk numbers. The final stage just after magnetization is labeling, QA and testing as well as packaging. Gen 7 comes standard with a well constructed test booth that has integrated wiring, equipment racks and support items for your test gear and platforms.

Supporting the main assembly system are the environmental and safety features that are critical to protecting your staff from exposure to hazardous fumes from adhesives and solder as well as other workplace hazards. Fume exhaust hoods, dual hand safety switches as well as a full complement of safety guards and systems are all standard on Gen 7 and all Phase Automation equipment.

Options include HMI and Active Air Control as well as network connectivity on the adhesive machines, shield magnet / cup assembly add-ons and more. Gen 7 is an existing platform that is designed to be tailored to your facility. Contact Phase Automation to learn more about Gen 7, the available options and details.

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Gen 8
The Gen 8 in the big brother to the Gen 7 and offers all of the features of the Gen 7 plus the capability to process up to 16" drivers. Similar to Gen 7, this is a complete, turnkey assembly system that allows your facility to process multiple sized drivers from raw parts to completed units, tested and ready to go in approximately 2 and a half hours without using exotic or expensive adhesives.

Gen 8 is a dual process system, with a central curing system and "mirrored" assembly processing systems on either side. Gen 8 will process 2" to 8" drivers on the "A" side with cycle times as low as 3 seconds and up to 16" drivers with cycle times as low as 8 seconds on the "B" side. Both sides feed into the centrally located high capacity curing system. Like it's little brother, Gen 8 was developed primarily for facilities located in low labor cost areas who still need precision controls and efficiency with the addition of needing to process high quantities of very large drivers. Due to the advanced curing system, Gen 8 systems deliver fantastically repeatable drivers, year after year and make your process practically immune to the seasonal climate variations that have such a drastic impact on adhesives and overall speaker performance.

Both sides of a Gen 8 system are comprised of multiple processing sections starting with the motor assembly. The Motor assembly section, including a staking press integrated with adhesive processing for front plates, a motor assembly workstation supported with Phase Automation's Pro 1385-Plus adhesive dispense platforms at the gluing stations. Gen 8 also includes a segmented pallet delay section which is connected to your ventilation system to enhance the workplace environment. Motors are completed in approximately 15 minutes, start to finish when used with typical acrylics and epoxies.

The driver assembly process is divided into three stages with the first two stages leading into a high capacity automated curing system. Single bead adhesive stations are supported by Pro 1385-Plus series adhesive machines and dual bead stations are supported by Pro 2385-Plus adhesive machines. The Pro 1385 and Pro 2385 machines are turntable based, high speed adhesive dispense platforms capable of cycle times of under 4 seconds while still maintaining 2+ Cpk numbers. The final stage just after magnetization is labeling, QA and testing as well as packaging. Gen 8 comes standard with a pair of well constructed test booths with

Running Gen 8 on the A or B side only is as simple as pushing a button; both sides are completely independent of one another in terms of electrical and mechanical operation. The centralized curing system is ""Siamesed"" to save space and when running both sides, run at higher efficiency.

Options include HMI and Active Air Control as well as network connectivity on the adhesive machines, shield magnet / cup assembly add-ons and more. Gen 8 is an existing platform that is designed to be tailored to your facility. Contact Phase Automation to learn more about Gen 8, the available options and details.

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Gen 9
The Gen 9 assembly system was developed in response to requests for a dual sided, high speed processing line for 2" to 8" drivers. Essentially, Gen 9 is a pair of Gen 7 systems paired up with a modified version of the Gen 8 curing system. The primary advantage of the Gen 9 over the Gen 8 is floor space savings for those facilities wanting to install multiple driver manufacturing systems or who have a Gen 8 on site and need additional capacity in the more popular (smaller) size drivers. The Gen 9 is a complete, turn key assembly system that allows your facility to process multiple sized drivers from raw parts to completed units, tested and ready to go in approximately 2 and a half hours without using exotic or expensive adhesives.

Gen 9 is a dual process system, with a central curing system and "mirrored" assembly processing systems on either side. Gen 8 will process 2" to 8" drivers on both sides of the system at very high speed. 3 to 4 second cycle times are not uncommon from both sides of a Gen 9. A facility operating 8 hour days at a 4 second average cycle rate will enjoy production of approximately 3.4 million drivers per year out of a single Gen 9 system. As with the Gen 8, both sides of the system feed into the centrally located high capacity curing system. Like Gen 7 and Gen 8, this system was developed primarily for facilities located in low labor cost areas who still need precision controls and efficiency with the addition of needing to process high quantities of very large drivers. Due to the advanced curing system, Gen 9 systems deliver fantastically repeatable drivers, year after year and make your process practically immune to the seasonal climate variations that have such a drastic impact on adhesives and overall speaker performance.

Both sides of a Gen 9 system are comprised of multiple processing sections starting with the motor assembly. The Motor assembly section, including a staking press integrated with adhesive processing for front plates, a motor assembly workstation supported with Phase Automation's Pro 1385-Plus adhesive dispense platforms at the gluing stations. Gen 9 also includes a segmented pallet delay section which is connected to your ventilation system to enhance the workplace environment. Motors are completed in approximately 15 minutes, start to finish when used with typical acrylics and epoxies.

The driver assembly process is divided into three stages with the first two stages leading into a high capacity automated curing system. Single bead adhesive stations are supported by Pro 1385-Plus series adhesive machines and dual bead stations are supported by Pro 2385-Plus adhesive machines. The Pro 1385 and Pro 2385 machines are turntable based, high speed adhesive dispense platforms capable of cycle times of under 4 seconds while still maintaining 2+ Cpk numbers. The final stage just after magnetization is labeling, QA and testing as well as packaging. Gen 9 comes standard with a pair of well constructed test booths with integrated wiring, equipment racks and support items for your test gear and

Options include HMI and Active Air Control as well as network connectivity on the adhesive machines, shield magnet / cup assembly add-ons and more. Gen 8 is an existing platform that is designed to be tailored to your facility. Contact Phase Automation to learn more about Gen 9, the available options and details.

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Gen X
The GenX assembly platform was designed and configured for companies operating in higher labor cost markets or those making higher value products. More specifically, we designed GenX for deployment to Europe and North America specifically for pro or sound reinforcement driver assembly in mind. GenX operators enjoy the benefits of robotic adhesive stations, automated or control assisted model change, rapid cycle time and extremely safe, efficient operation. Station cycle time is largely dependent on staff capability; typical machine cycle times are under 10 seconds for any given operation. The name “GenX” refers to the basis of this system being found in Phase Automation’s 10th generation of driver assembly platforms.

The GenX platform is currently designed in two base configurations. The Sierra configuration (“GenXs”) is configured with a full complement of robotic and labor saving devices but relies on manual loading of the driver motor assembly section. The Apollo configuration (“GenXa”) is configured for fully automated motor assembly with minimal operator interaction required.

GenX is a semi automated speaker assembly system. Depending on base configuration, the GenX system is delivered with approximately 20 automated stations on the motor assembly section and approximately 30 automated stations or processes on the main assembly section.

Regardless of configuration, GenX has the capacity to process speakers up to 21” diameter. Cycle time is operator dependant; considering typical operator efficiency, cycle times can be as low as 15 seconds even for large, professional application drivers. Note that in the GenXa configuration the motor assembly section cycle time is designed to run at a cycle time of approximately 15 seconds.

GenX Motor Assembly – At the heart of the Gen 10 motor assembly system is the Mitsubishi Q series Motion control / PLC platform which controls the integrated robotics, adhesive dispense systems, AC motors and numerous sensors and logic gates. Main interface is via 10.4” touch screen with data point, Ethernet and RS 232 communication ports available to your process engineering staff. The system contains three additional station ready touch screens in addition to the main panel- other screens are also color, 5.7” and are located at appropriate points throughout the system where they can provide access to setup, controls and data.

The GenX Main Assembly - The main assembly system is run based on the same Mitsubishi Q series Motion control / PLC system with some additional expansion. Connectivity to your facility network is standard via built in Ethernet ports. Similar to the motor assembly system, the main assembly section is based on a free-flow pallet concept running on a transit roller chain drive. The transit chain is robust and a proven performer with Phase and many other manufacturing facilities throughout the world.

Primary control and monitoring is performed via a centralized 10.4” color touch screen display. This gives your production engineering staff access to all features and the ability to adjust literally hundreds of points in the system. The main control panel can access and display subsystem status such as individual adhesive machines, pallet advance speed or even the speed at which the Vertical Time Delay System will cycle. Many of the individual work stations or robotics have integrated 5.7” color touch screens as well. This gives the setup crew or properly authorized operators the access to control and adjust the machine to suit a given condition.

With one process exception, all of the adhesive dispense systems in the system are based on Phase Automation’s in house robotics platform. All robotics in the line are from the SR series; these are servo driven coupled to high precision ball screw positioning with hardened box way bearing transit assemblies. The use of ball screw positioning in adhesive machines sets a new standard for precision and reliability in the speaker industry.

There is zero offline handling required to complete the assembly of a speaker unit. The Vertical Time Delay System or VTDS is a space saving, offline delay system that automatically moves the work in progress into an integrated overhead delay conveyor where the speakers are allowed to “age” for adhesive curing. . This system takes minimal floor space (under 2 square meters) and delivers a time delayed cure of the critical adhesives just prior to final testing. GenX controls and control features are quite advanced compared to the typical

In standard configuration, GenX is delivered with a Mitsubishi Q series based PLC. The Q series delivers fantastic integration of motion control, process management and communications both within the system and to external connections such as your company’s Ethernet. The communication capabilities of the Q series open up countless possibilities for your process engineers to continually monitor, refine and improve your process for higher yield and profitability. The Q series PLC platform is multi-CPU capable which adds even more possibilities for optional expansion and redundancy.

Control cabinets, panel and junction boxes are assembled and wired to the highest degree of professionalism by our expert electrical technicians. Separate panels for main power (3 phase and single phase) is separated from the main control section for safety and each panel can be appropriately “locked out’ by your maintenance staff should the need arise. Power and signal distribution to the output devices is done through the use of modular relay boards developed in house at Phase Automation. The relay boards contain 16 relays each and are easily accessed in the main control panel or in one of 6 sub panels situated throughout the GenX system.

Options for the GenX platform are practically unlimited. Phase Automation offers GenX and most other models with Omron, Mitsubishi or Allen Bradley control systems depending on your preference and budget. Additional robotic systems, assembly stations or entire off-line subassembly lines are available as modular or custom options. GenX can be configured for use with conventional adhesives in conjunction with an automated curing system.

Contact Phase Automation for more information about the GenX system, capabilities and options.