Adaptive Innovations / Toggled

Automated Assembly Machine

We worked with Adaptive Innovations to design and build a fully automated assembly machine that produces T8 and T12 LED fluorescent bulb replacements for their client, TOGGLED. We provided the automation system architecture and high level design, designed and programmed the HMI system, the part tracking and traceability system, servo axis control of four assembly stations, TCP/IP and serial communication device driver infrastructure and co-invented a hot-bar soldering system. The products from this machine are now available through Home Depot The system consists of the following components:

  • 5 Fanuc Robots
  • 6 Keyence Visual Inspection Cameras (TCP/IP)
  • 3 Cognex Fixed 2D Barcode Scanners (TCP/IP)
  • 4 Cognex Handheld 2D Barcode Scanners (TCP/IP)
  • 2 Videojet Printers
  • 2 Hikoi Electrical Testers (serial)
  • 2 Chroma Programmable Power Supplies (serial)
  • 2 Chroma Programmable Load Simulators (serial)
  • 2 Cencorp Laser Markers (TCP/IP)
  • 18 Assembly Stations with 2+ Servo Axes, Pneumatic Devices, etc
  • Part Tracking and Consumable Traceability System
  • Co-Invented Hot Bar Soldering System (patent pending)
  • HMI System Consisting of 4 Touch Screen Panels



Adaptive Innovations is an industrial automation and custom equipment designer, machine builder & equipment integrator located in Lakewood Colorado.

TOGGLED is a USA company focused on next-generation solid-state lighting technology. The company was formed in 2007 as a spinoff venture and is a wholly owned subsidiary of Altair.

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