Rollon precision system solution helps JR Automation deliver increased medical device assembly speed

JR Automation – a global leader in connected industrial automation and system integration, and part of the Hitachi Group of Companies – has been a trusted name since its founding in 1980, boasting a strong global presence, with over 20 manufacturing facilities worldwide. Known for providing innovative solutions in sectors such as automotive, aerospace, life sciences, and consumer goods, JR Automation has carved out a significant presence in the medical device assembly market, serving customers with complex needs.

“Customers approach us in a variety of ways” says Mark Faris, Manager of Project Management at JR Automation. “Some come with a clear vision of what they need and provide a detailed list of requirements. Others, however, bring us a broader concept and look to us for help in bringing it to life. For instance, they might have a prototype, but they’re unsure about how to scale it for production. We collaborate closely with these customers, reviewing their designs, suggesting modifications, and providing as much support as we can to make their vision a reality. This approach sets us apart from many other system integrators”.

Recently, JR Automation partnered with Rollon, a leading provider of linear motion solutions, to address unique challenges in a high-precision medical device assembly project. This case study explores the project, detailing the challenges faced, the solutions implemented, and the impressive results achieved through Rollon’s TH linear actuators.

The challenge

JR Automation needed to design a system capable of assembling, inspecting, and palletizing medical devices in a cleanroom environment. The system required multiple interconnected stations to function seamlessly, while meeting stringent requirements for speed, accuracy, and payload.

Finding a solution that could balance high speed with the precision required for medical auto injector device assembly was a significant challenge, as existing solutions in the market are often compromised between speed, payload or accuracy, without a single option meeting all the project’s requirements.

The solution: Rollon’s TH linear actuators

When JR Automation contacted Rollon to address these challenges, they selected Rollon’s Precision System TH linear actuators, which provided the necessary precision, repeatability, and speed. TH linear actuators are ball screw driven linear units with a compact design, making them ideal for applications where space is limited.

Rollon’s Precision System TH linear actuator.

The TH series stood out for its:

• High accuracy: the TH actuators provided +/- 5-micron repeatability, essential for maintaining quality and consistency in the assembly process.
• Payload capacity: with a strong payload capability, the TH units could handle the assembly and palletizing tasks without sacrificing speed or accuracy.
• Versatility: the standard off-the-shelf units could be deployed in the end customer’s cleanroom environment without modification, while still meeting the strict cleanliness standards necessary for medical device manufacturing.

In total, 850 TH actuators have been installed to date across multiple assembly lines, along with 150 Rollon’s Smart series belt-driven actuators in an H-Bot configuration for palletizing. The Smart actuators also played a crucial role in positioning cameras for accurate sensing in the palletizing process and in handling trays prepared for cleaning.

Results

The deployment of Rollon’s TH actuators helped JR Automation deliver a solution that collaborated in enhancing the production capacity, while maintaining the precision required. This increase in throughput, combined with the TH actuators’ high level of accuracy and repeatability of the TH actuators, ensured a successful outcome for the project.

“Rollon’s TH actuators stood out for their exceptional repeatability, payload capacity, and operational speed. These were critical factors for us, and Rollon was the only provider that met all our requirements without compromise. While other solutions offered repeatability, they fell short in accuracy, speed, or payload capacity we needed. That’s why we ultimately chose Rollon” says Joseph Naranjo, Mechanical Project Engineer at JR Automation.

A collaborative effort based on trust and communication

The collaboration between JR Automation and Rollon is built on mutual understanding and shared values. From the initial system review to the project’s completion, Rollon provided extensive technical support, ensuring JR Automation had the flexibility to adapt to changing requirements.

“We first started working with JR Automation back in 2018 with a single system sale. After that, we collaborated on a series of smaller projects, which also involved using Compact Rail linear guides, but it was this major project that really deepened our partnership and led the JR Automation team to adopt our products on a larger scale” says Matthew Martin, Rollon’s representative for Virginia, North Carolina, South Carolina, and Tennessee. “For this large-scale project, we conducted a thorough review of each station within the system, collecting as much information as possible to offer well-informed feedback. JR Automation needed flexibility to adjust speed and payload as required. Our goal was to ensure JR Automation had the capacity to adapt and meet the evolving demands of their customers”.

“JR Automation doesn’t offer one-size-fits-all designs. Instead, we start with reliable standard products and tailor them to meet the specific needs of our customers. Our customers trust us to deliver quality solutions, and so we want to be confident that what we’re providing is rock-solid. That means extensive proof of principle, rigorous testing, and leveraging insights from other projects. It’s a high-risk business, but Rollon helps us mitigate that risk. The support and responsiveness of Rollon’s engineers make a significant difference for us” concludes Faris.

Conclusion

By choosing Rollon’s TH linear actuators, JR Automation achieved its objectives and set a new standard for precision and efficiency in medical device assembly. As JR Automation continues to grow and enter new markets, Rollon remains a key partner in delivering high-performance linear motion solutions that meet the most demanding industry standards. The two companies are already collaborating on the delivery of two additional lines for the assembly of medical devices.

For more information on Rollon’s linear motion solutions and to connect with Rollon application engineers in your area, or region contact us.