The PSA-1341 Data Traceability and Automation System is a fully integrated production platform designed to automate assembly, testing, and data capture across the Air er and CSD (Condensate Separator Device) manufacturing process.
System Overview:
It provides real-time visibility, machine-to-server data synchronization, and complete product traceability with automated Poka-Yoke (mistake-proofing) controls at every stage. System Overview
The server logs all inspection data, including test results, thermal profiles, and barcode-based product identifiers, ensuring complete traceability across the entire assembly process.
Each test and assembly station — including Grommet Pressing, Screwing & Labeling, Completeness Checking, and CSD Leak Testing — communicates with the central data server over Modbus TCP or RS-485.
All process results, operator IDs, and barcode data are automatically logged and stored in a secure CSV/SQL database.
The system ensures 100% quality verification of all units produced and eliminates manual recording errors.
Key Features:
- 1. Multi-Station Integration
- Supports synchronized communication across all PSA-1341 test benches:
- CSD-1 Grommet Assembly & Leak Test Station
- CSD-2 Completeness Checking Station
- CSD-2 Negative Leak Testing with Zebra Label Printing
- Final EOL Machine with Barcode Validation and Poka-Yoke Interlock
- All machines are networked to the main data server for centralized monitoring.
- 2. Centralized Data Logging
- Real-time collection of test results, timestamps, and barcodes.
- Automated data transfer from PLCs via Modbus TCP.
- Shift-wise performance reports and auto-backup.
- Secure storage in structured SQL/CSV databases for audit traceability.
- 3. Functional & Leak Testing
- Dual-stage leak test validation using ATEQ leak testers.
- Configurable vacuum/pressure test modes for CSD components.
- Auto-result classification (PASS/FAIL) and digital signature logging.
- Integration with Zebra printer for automatic traceability label generation.
- 4. Intelligent Monitoring & Poka-Yoke
- Real-time dashboards for test status and machine health.
- Process interlocks prevent operation without barcode scanning or correct part placement.
- Visual and buzzer alarms for NOK conditions.
- Operator authentication and shift identification for accountability.
System Benefits:
- 100% digital traceability of all test data.
- Zero operator dependency for data entry.
- Instant OK/NOK decision and data backup.
- Seamless communication with main Modbus data server.
- Compliance with IATF 16949 / ISO 9001 automotive quality standards.
Application Areas:
- Air er and CSD module assembly lines.
- Leak and functional testing for plastic and aluminum housings.
- Barcode-based end-of-line traceability systems.
- Automotive component production with data analytics integration.
