Process layout
This machine tending automation solution utilizes YASKAWA robots in conjunction with press machines to automate the loading of workpieces for the expansion of cylindrical metal products, significantly enhancing process safety.
Due to the nature of press operations—characterized by extremely short cycle times and high-risk environments—industrial accidents are a frequent concern.
By automating the entire sequence from workpiece infeed and discharge to continuous press forming, this solution drastically increases productivity while minimizing the operator's management touchpoints.
Components
| Robot |
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Workflow
| STEP 1. | Infeed: Workpieces move to the operating position via the infeed conveyor. |
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| STEP 2. | Picking: The robot picks raw material from the loading box. |
| STEP 3. | Initial Forming: The robot moves the material to the 1st forming press. |
| STEP 4. | Calibration: Positioning of the raw material is corrected for precise alignment. |
| STEP 5. | Loading (1st Stage): The robot picks the semi-finished part from the 1st press and loads new raw material. |
| STEP 6. | Secondary Forming: The robot moves the semi-finished part to the 2nd forming press. |
| STEP 7. | Swapping (2nd Stage): The robot picks the final completed part and unloads the semi-finished part into the 2nd press. |
| STEP 8. | Discharge: The finished product is unloaded onto the discharge conveyor. |
| STEP 9. | Layer Management: Once a full layer in the loading box is processed, the robot removes the interlayer tray to access the next batch. |
Features
Simultaneous Work Environment Improvement and Productivity Boost
Continuous Operation: Maximizes productivity through non-stop, seamless work cycles with zero idle time.
Safety Assurance: Prevents industrial accidents by isolating workers from high-risk forming zones.
Optimized Design and Pre-Verification
Multipurpose Tooling: Expertly designed end-of-arm tooling (EOAT) capable of handling formed products, interlayer trays, and even boxes with a single robot.
Cost Efficiency: Utilizes existing loading boxes as-is, minimizing additional infrastructure costs.
Simulation-Based Validation: Conducts 3D simulations to perform interference checks and verify cycle time performance before on-site installation.
Results
| Key Benefits | Increased productivity through reduced cycle times.
Enhanced workplace safety by eliminating the risk of press-related accidents.
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| Client Feedback | We were able to implement automation with minimal changes to our pre- and post-processing because the system allowed us to reuse our existing boxes. Furthermore, G-TEC’s outstanding gripper design enables a single robot to handle everything from the products to the trays and boxes, leading to a highly satisfying automation result.
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