Process layout
This automation solution utilizes the Doosan M1509 collaborative robot to support metal machining operations in a Machining Center (MCT). The project was designed to improve production efficiency, reduce defect rates, and enhance operational workflow by automating simple, repetitive tasks.
In the previous process, workers had to stand by the equipment constantly to manually load each workpiece. By delegating the loading and unloading tasks to the robot, operators can now manage and run multiple machines simultaneously. Furthermore, by implementing Gun Solution's technology, the robot can perform tasks in the same manner as a human operator even on older legacy machine tools, effectively reducing costs associated with separate hardware interfaces.
Components
| Robot |
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Workflow
| STEP 1. | Load raw materials into the pallet. |
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| STEP 2. | Robot picks up the raw material. |
| STEP 3. | Load the material into the jig inside the Machining Center (MCT). |
| STEP 4. | Secure the material (Activate hydraulic switch). |
| STEP 5. | Close the MCT door. |
| STEP 6. | Push the "Start" switch. |
| STEP 7. | Machining process begins. |
| STEP 8. | Clean the part via air-blowing. |
| STEP 9. | Pick up the finished product. |
| STEP 10. | Unload the part back to its original position on the pallet. |
| STEP 11. | Clean the jig inside the MCT for the next cycle. |
Features
Maximized Flexibility & Compact Installation through Collaboration
Human-Robot Synergy: Efficiency is boosted by having humans manage the overall workflow while the robot performs continuous, repetitive tasks.
Space-Efficient: Utilizes compact collaborative robots (cobots) to minimize the footprint required for installation, avoiding floor space congestion.
Enhanced Safety: Prevents workplace accidents by implementing high-safety cobots designed to work alongside human operators.
User-Friendly Robot Teaching
Legacy Machine Compatibility: Robots can be taught to operate exactly like a human, eliminating the need for expensive hardware interfaces even on older machine tools.
Direct Teaching: Supports intuitive "Direct Teaching," allowing users to manually move the robot arm to set positions.
Compliance Control: Uses torque sensors for compliance control, enabling the robot to perform delicate tasks like pressing a part firmly into a chuck.
Rapid Changeover: Even when product models change, additional teaching can be completed in under 10 minutes.
Work Safety & Quality Assurance
High-Sensitivity Collision Detection: Equipped with 6-axis torque sensors (0.2Nm resolution) that detect sensitive collisions from any direction to trigger an immediate emergency stop.
Soft Response Logic: Applies compliance control logic that reacts smoothly to external forces during picking and unloading, minimizing impact and protecting the product.
Heavy-Duty Performance: Utilizing a 15kg high-payload cobot allows for the automation of heavy-duty tasks that were previously difficult for standard collaborative robots.
Results
| Key Benefits | Increased operational efficiency by allowing existing workers to take on additional high-value tasks.
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| Client Feedback | Most of our products have long machining cycles, which meant workers were wasting time just standing by the machines. Now, the robot handles the machining process while the operator only needs to swap out pallets periodically. This shift has drastically increased our overall work efficiency.
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