Bumper Gate Cutting and Transfer Automation using Two Yaskawa Robots

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Bumper Gate Cutting and Transfer Automation using Two Yaskawa Robots

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Application Field: Industry > Automotive, Application > Injection·Ejection, Sector > Manufacturing

Industry > AutomotiveApplication > Injection·EjectionSector > Manufacturing

#GateCutting#InjectionMolding#BumperHandling#YaskawaRobot#VacuumGripper#ConveyorTracking#MaterialTransfer#CycleTimeReduction

Process Overview

This transfer automation solution uses two Yaskawa robots and vacuum grippers to perform gate cutting on automotive bumper injection molded parts and transfer them to a conveyor tray.

The system accurately picks curved and flexible bumper parts, performs gate cutting, and applies conveyor tracking technology to load parts onto continuously moving conveyor trays.

By enabling continuous operation without stoppage or idle time, the solution maintains high productivity throughout the process.

Components

Robot	Yaskawa GP225 x 2 units 6-axis articulated robot Payload: 225 kg Working range: 2,702 mm Weight: 1,080 kg Repeatability: ±0.2 mm
Peripherals	Tool: vacuum gripper for gate cutting x 2 stages Tool: vacuum gripper for tray transfer x 1 stage Peripheral devices: robot mounting base x 2 units Gate cutting machine and scrap collection unit Workpiece infeed conveyor Sticker labeling unit Tray conveyor PLC and control panel Conveyor tracking unit (encoder, trigger sensor) Safety fence

Workflow

STEP 1.	Pick two molded parts from the injection machine and perform gate cutting
STEP 2.	Load the molded parts onto the belt conveyor
STEP 3.	Move and fix at the end of the conveyor
STEP 4.	Pick the workpiece
STEP 5.	Apply sticker labeling
STEP 6.	Wait for tray conveyor position
STEP 7.	Load onto the tray conveyor synchronized with conveyor speed

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Features

Enables optimized system design tailored to the process
Ensures precise cutting and transfer operations for complex-shaped and flexible materials
Designs and manufactures vacuum grippers optimized for automotive bumper geometry
Enables optimized tool design and manufacturing based on process conditions and performance requirements
Enables continuous operation without stoppage or idle time using conveyor tracking technology, maintaining high productivity
Minimizes management points by performing additional processes such as sticker labeling within the same workflow
Minimizes failure rates through pre-validation
Enables pre-validation of interference and operational performance through offline simulation

Results

Key Benefits	Minimization of loading labor Reduced idle waiting time
Client Feedback	We were able to minimize loading labor and reduce idle time, improving overall productivity.

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