Process layout
This machine tending automation solution utilizes the Doosan M1013 collaborative robot to automate the hazardous task of exchanging tools in shrink-fit chucks.
In industrial settings, shrink-fit chucks are used to enhance machining precision and create compact tool assemblies. However, because the process involves repeated cycles of rapid heating and cooling, operators were previously exposed to high risks of safety accidents, such as thermal burns.
By implementing Doosan’s collaborative robot, the risk of safety accidents has been eliminated, and productivity has increased through continuous, uninterrupted operation.
Components
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Workflow
| STEP 1. | Picking: The robot picks a chuck from the supply pallet. |
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| STEP 2. | Preparation: The chuck dimensions are measured, and it is placed into an air-blowing device for cleaning. |
| STEP 3. | Tool Staging: The replacement tool is picked and unloaded into the shrink-fit station. |
| STEP 4. | Chuck Loading: The robot picks the cleaned chuck and loads it into the shrink-fit station. |
| STEP 5. | Heating: The induction device heats the chuck to expand the bore. |
| STEP 6. | Extraction: The robot picks and removes the existing (old) tool from the heated chuck. |
| STEP 7. | Insertion: The robot inserts the new replacement tool into the expanded chuck. |
| STEP 8. | Completion: The robot picks the completed assembly and unloads it onto the chuck pallet. |
Features
Establishing a Safe Working Environment
Hazard Replacement: Safely replaces manual tasks that carry high risks of safety accidents, such as thermal burns from high-temperature heating.
Improved Production Efficiency
Continuous Operation: Maximizes productivity by performing seamless, non-stop work cycles with minimal idle time.
Easy Work Teaching
Direct Teaching: Operators can set up new tasks intuitively by manually moving the robot arm.
Compliance Control via Torque Sensors: Enables high-precision tasks, such as seating tools perfectly into chucks, by utilizing the robot's ability to sense and adapt to physical contact.
Rapid Changeovers: Even when switching to different tool models, additional teaching can be completed in under 10 minutes.
Enhanced Operational Safety
Omnidirectional Sensitivity: Equipped with high-resolution torque sensors (0.2Nm) on all 6 axes, allowing the robot to detect and stop immediately upon the slightest collision from any direction.
Shock-Minimizing Logic: Applies compliance control during picking and unloading to react softly to external forces, minimizing potential impact on workpieces.
Compact Installation
Space Optimization: The small footprint of the collaborative robot allows for installation in tight spaces without the need for large safety cages.
Results
| Key Benefits | Improved workplace safety (Prevention of burns and other thermal accidents).
Increased operational efficiency by allowing workers to focus on higher-value tasks.
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| Client Feedback | We are highly satisfied as the system has eliminated hazardous tasks like heat handling while significantly boosting productivity by minimizing downtime.
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