Steel Plate Press Assistance using Dual Yaskawa Robots

Industry > Metal·PlasticsApplication > Machine TendingSector > Manufacturing

This automation solution utilizes two YASKAWA robots to assist in steel plate press operations. By automating the machine tending process, the system secures high operational stability and safety.

Due to the nature of press processes—characterized by extremely short cycle times and high-risk environments—industrial accidents involving human operators are frequent.

In this specific solution, the robots hold the workpieces during the pressing operation itself. By having two robots perform continuous, synchronized cross-work, the cycle time is minimized to just 2 seconds per unit, maximizing overall productivity.

Components

Robot	Robots: 2 units of YASKAWA GP7 High-speed 6-axis articulated industrial robots. Payload: 7kg Reach: 927mm Weight: 34kg Repeatability: ±0.01mm (Ultra-high precision)

Workflow

STEP 1.	Infeed: Workpieces move to the operating position via the infeed conveyor.
STEP 2.	Picking (Robot 1): Robot 1 picks up two workpieces (2 EA).
STEP 3.	Synchronized Cycle: While Robot 1 holds the parts during the press operation, Robot 2 simultaneously picks up the next two workpieces.
STEP 4.	Cross-Work: As Robot 1 moves to the discharge jig with the finished parts, Robot 2 immediately moves into the press to perform its operation.
STEP 5.	Repetition: Robot 1 picks up the next set of products, and the continuous cycle repeats.

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Features

Simultaneous Improvement of Work Environment and Productivity

Dual-Part Handling: Capable of processing two workpieces simultaneously, achieving an impressive cycle time of just 2 seconds per unit.

In-Hand Pressing: The robot holds the workpiece during the compression process, minimizing standby and transfer times.

Tandem Cycle Optimization: By using two robots in a synchronized cross-work pattern, the overall cycle time has been reduced by 50%.

Integrated Collision Avoidance: Equipped with advanced logic to prevent interference when controlling two robots simultaneously in the same workspace.

Safety Assurance: Fundamentally prevents industrial accidents by automating high-risk manual tasks.

Custom Design and Pre-Verification

Optimized Tooling: Custom end-of-arm tooling (EOAT) designed to handle two workpieces at once, specifically engineered for the high-speed layout.

Expert Integration Capability: Extensive expertise in designing and manufacturing diverse tools for complex automation needs.

Simulation-Based Validation: Utilizes 3D simulation to conduct interference checks and verify performance benchmarks before on-site installation.

Results

ROI Period	24 months
Key Benefits	50% reduction in cycle time. 100% increase in overall productivity.
Client Feedback	Despite the extremely demanding tact time requirement of 2 seconds per unit, G-TEC proposed and implemented a variety of innovative solutions that allowed us to successfully meet our production targets.