Wheel Machining Support Automation with ABB IRB 6640

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Wheel Machining Support Automation with ABB IRB 6640

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Application Field: Industry > Automotive, Application > Machine Tending, Sector > Manufacturing

Industry > AutomotiveApplication > Machine TendingSector > Manufacturing

#WheelMachining#MachineTending#ABBIRB6640#TurningCenterAutomation#HighPayloadHandling#CycleTimeReduction#TwoMachineSupport#ErgonomicsImprovement

Process Overview

This solution automates machine tending for machining high-payload automotive wheels using an ABB IRB 6640 robot.

Since automotive wheels are heavy workpieces (over 8 kg) that are difficult and physically demanding for operators to handle, robot automation supports two machining centers at the same time, improving productivity and operator satisfaction.

Components

Robot	ABB IRB 6640 6-axis articulated robot Payload: 235 kg Working radius: 2,550 mm Weight: 1,310 kg Repeatability: ±0.05 mm IP67
Peripherals	WIA L600AW turning center (x2, separate equipment) Dual pneumatic gripper Robot mounting base Workpiece infeed conveyor Workpiece outfeed conveyor

Workflow

STEP 1.	Pick workpiece
STEP 2.	Load into machine tool
STEP 3.	Pick finished workpiece
STEP 4.	Unload to outfeed conveyor

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Features

Improves both work environment and productivity
Prevents operator musculoskeletal disorders by automating high-payload (over 8 kg) handling
Minimizes idle time by supporting two machining centers simultaneously
Supports optimal design and pre-validation based on process conditions
Supports custom tool design and fabrication optimized for process conditions and performance
Enables stable gripping through tool design optimized for automotive wheel geometry
High durability and high protection rating
- IP67 protection for harsh machining environments
- High reliability with an ABB industrial robot designed for low failure rates

Results

Key Benefits	Higher productivity through reduced cycle time Prevention of operator musculoskeletal disorders
Client Feedback	This process was physically demanding due to high-payload product handling. With automation, operators were reassigned to other processes, improving work efficiency and productivity.

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