Powder Compaction Press Assistance using Doosan M1013

Industry > Metal·PlasticsApplication > Machine TendingSector > Manufacturing

This automation solution utilizes the Doosan M1013 collaborative robot to automatically load and stack powder-compacted cutting tool components onto pallets. This system is characterized by its rapid teaching capabilities and high workplace safety.

The powder compaction process traditionally generates significant amounts of dust, creating a hazardous environment for human workers. By implementing robot automation, idle time has been minimized to allow for continuous operation. Furthermore, a 100% inspection process has been integrated into the workflow, successfully reducing the overall defect rate.

Components

Robot	Robot: Doosan M1013 6-axis articulated collaborative robot with 6 integrated torque sensors. Payload: 10kg Reach: 1,300mm Repeatability: ±0.05mm Weight: 33kg

Workflow

STEP 1.	Picking: The robot picks the finished product after the press forming process is complete.
STEP 2.	Cleaning: The product is placed into an air-blowing device to remove residual powder and dust.
STEP 3.	Inspection: The robot unloads the product onto a scale to measure weight and determine if it meets quality standards (Pass/Fail).
STEP 4.	Error Handling: If a defect is detected, the system triggers an alarm for operator notification.
STEP 5.	Stacking: High-quality products are accurately unloaded and stacked onto the discharge pallet.

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Key Features

Improved Production Efficiency and Quality

Continuous Operation: Minimizes idle time through seamless task execution, significantly boosting production efficiency.

100% Inspection: Integrates automated weighing and inspection to minimize defect rates and ensure consistent quality.

Safe Working Environment

Dust Hazard Mitigation: Eliminates human exposure to the fine, hazardous dust generated during the powder compaction process.

Easy Work Teaching

Direct Teaching: Allows operators to set up and adjust points intuitively by manually moving the robot arm.

Compliance Control via Torque Sensors: Enables high-precision handling, ensuring parts are perfectly aligned with fixtures or jigs through sensitive force feedback.

Rapid Changeovers: Facilitates model changes with additional teaching completed in under 10 minutes.

Enhanced Operational Safety

Omnidirectional Sensitivity: High-resolution torque sensors (0.2Nm) on all 6 axes allow the robot to detect and react to the slightest collisions from any direction.

Shock-Minimizing Logic: Applies compliance control during picking and unloading to react softly to external forces, protecting both the robot and fragile "green" compacts.

Compact Installation

Space Optimization: The collaborative robot’s small footprint allows for easy integration into existing lines without the need for large safety enclosures.

Implementation Results

ROI Period	18 months
Key Metrics	Improved workplace environment (Removal of hazardous dust-related labor). Enhanced defect detection and response through integrated 100% inspection.
Client Feedback	Our workers had to wear masks constantly due to fine dust, making this a highly avoided task. By automating the process and adding 100% inspection, we improved both productivity and quality simultaneously.