Differential Case Machining Support using FANUC Robot for Doosan Turning Center

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Differential Case Machining Support using FANUC Robot for Doosan Turning Center

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

Industry > AutomotiveApplication > Machine TendingSector > Manufacturing

#MachineTending#TurningCenterAutomation#FANUCRobot#LinearTrack#GantryRobot#DoosanTW2600M#AutomatedHandling#FactoryProductivity

Process Overview

This solution uses the FANUC M-20iA/35M robot installed on an upper linear track mounted above Doosan turning machines (TW2600M) to machine differential cases for automotive applications.

By installing the robot together with a linear track on top of the machine tool, the system enables efficient floor space utilization and automates continuous processes in a single integrated workflow, significantly improving automation efficiency.

Since the front side of the machine tool remains open, smooth access is available for tool change and machine maintenance operations.

In addition, it helps prevent musculoskeletal disorders for operators by automating the loading and unloading of heavy machined parts.

Components

Robot	FANUC M-20iA/35M x 2 units 6-axis articulated robot Payload: 35 kg Working range: 1,813 mm Weight: 252 kg Repeatability: ±0.03 mm IP rating: IP67 (arm), IP54 (body) Robot-mounted axis: 7-axis
Peripherals	Tool: pneumatic double gripper x 2 units Equipment: Doosan Turning Center TW2600M x 6 units (OP10 x 3 units, OP20 x 3 units) Peripheral devices: mobile robot base (linear track), TRG (Top Robot Gantry) series by Youngchang Robotech OP10: workpiece infeed lift feeder, workpiece gripping correction jig x 3 sets, 1st machining completed jig OP10–OP20 transfer: gantry robot for inter-process transfer (3-axis) OP20: infeed waiting jig, air blowing unit Outfeed: gantry robot for discharge (2-axis), discharge jig Safety fence

Robot

FANUC M-20iA/35M x 2 units
6-axis articulated robot
Payload: 35 kg
Working range: 1,813 mm
Weight: 252 kg
Repeatability: ±0.03 mm
IP rating: IP67 (arm), IP54 (body)
Robot-mounted axis: 7-axis

Peripherals

Tool: pneumatic double gripper x 2 units
Equipment: Doosan Turning Center TW2600M x 6 units (OP10 x 3 units, OP20 x 3 units)
Peripheral devices: mobile robot base (linear track), TRG (Top Robot Gantry) series by Youngchang Robotech
OP10: workpiece infeed lift feeder, workpiece gripping correction jig x 3 sets, 1st machining completed jig
OP10–OP20 transfer: gantry robot for inter-process transfer (3-axis)
OP20: infeed waiting jig, air blowing unit
Outfeed: gantry robot for discharge (2-axis), discharge jig
Safety fence

Workflow

STEP 1.	Pick workpiece from the lift feeder (OP10)
STEP 2.	Load into turning center and perform machining
STEP 3.	Perform part alignment for completed parts
STEP 4.	Place onto 1st machining completed jig
STEP 5.	Transfer to OP20 using inter-process gantry robot
STEP 6.	Load into turning center for 2nd machining (OP20)
STEP 7.	Load finished part into air blowing unit
STEP 8.	Transfer to discharge jig using outfeed gantry robot

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Features

Improved Productivity and Operational Efficiency

Minimizes cycle time using a high-speed, high-precision industrial robot
Uses one robot to handle three machine tools, minimizing idle time by matching machining takt time
Enables optimized layout configuration based on the number of machining machines
Minimizes management points and enables continuous production by applying infeed/outfeed conveyors
Prevents musculoskeletal disorders caused by heavy material handling

Maximized Space Utilization Through an Optimized Layout

Minimizes floor space usage and maximizes space efficiency by mounting the robot above the machine tool
Ensures accessibility for maintenance by keeping the front side of the machine tool open

Results

Key Benefits	Minimization of loading labor Improved productivity by reducing idle waiting time
Client Feedback	Since the workpieces were heavy and required continuous fast handling, it was difficult for operators to keep up. By adopting robot handling, the process became easier and operators were relieved from heavy-load tasks, resulting in higher satisfaction.

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