Automotive Wheel Handling Automation Using Yaskawa Robot

Industry > AutomotiveApplication > Loading·UnloadingSector > Manufacturing

#WheelHandling#MaterialHandling#YaskawaRobot#GP180#HeavyPayloadAutomation#ChainConveyor#CycleTimeReduction#ErgonomicSafety

Process Overview

This loading/unloading automation solution uses a Yaskawa robot to automate handling processes for heavy workpieces such as automotive wheels.

For automotive wheels, which are heavy workpieces weighing over 8 kg, manual handling is physically difficult and often avoided by operators. Through robotic automation, the system can handle two wheels simultaneously, increasing productivity while improving operator satisfaction.

Components

Robot	Yaskawa GP180 6-axis articulated robot Payload: 180 kg Working range: 2,702 mm Weight: 1,020 kg Repeatability: ±0.2 mm
Peripherals	Tool: scissor-type pneumatic gripper x 2 units Peripheral devices: robot mounting base Workpiece infeed/transfer chain conveyor Discharge pallet Workpiece hanger detection sensor and positioning guide PLC and control panel Safety fence (not included in the above image)

Workflow

STEP 1.	Workpiece moves to the target position via infeed/transfer conveyor
STEP 2.	Positioning guide engages when the workpiece is detected
STEP 3.	Robot picks the wheel
STEP 4.	Load onto the discharge pallet

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Key Features

Improves both working environment and productivity at the same time
Prevents musculoskeletal disorders by automating heavy product handling (8 kg or more)
Shortens cycle time by handling two workpieces simultaneously
Performs continuous operation while maintaining transfer tasks via the conveyor
Enables optimized design and pre-validation based on process conditions
Enables optimized tool design and manufacturing based on process conditions and performance requirements
Designs tools and layouts to enable simultaneous handling of two workpieces
Enables accurate picking even under high-variability conditions (chain conveyor characteristics)
Enables pre-validation of interference and operational performance through offline simulation

Implementation Results

ROI Period	24 months
Key Metrics	Improved productivity through reduced cycle time Prevented musculoskeletal disorders for operators
Client Feedback	Since handling heavy products was physically demanding, operators struggled with the process. Through automation, we were able to reassign operators to other processes and improve both work efficiency and productivity. We initially thought automation would be difficult due to chain conveyor instability and vibration, but we succeeded with the J-Tech solution.

Automotive Wheel Handling Automation Using Yaskawa Robot

Application Field: Industry > Automotive, Application > Loading·Unloading, Sector > Manufacturing

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