Process layout
This machine tending automation solution utilizes the Doosan M1013 collaborative robot to automate the loading and unloading of workpieces for end mill machining in a machining center.
Previously, operators had to remain stationed at the machine to manually feed and remove workpieces for every cycle. With this solution, the robot takes over the loading and unloading tasks, allowing the human operator to manage multiple machines simultaneously, significantly boosting overall labor efficiency and productivity.
Components
| Robot |
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Workflow
| STEP 1. | Picking: The robot picks raw material from the supply pallet. |
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| STEP 2. | Loading: The robot places the workpiece into the machining center chuck (fixture). |
| STEP 3. | Seating: The robot uses a urethane pad to press the workpiece down, ensuring it is perfectly seated. |
| STEP 4. | Locking: An electric screw tool (integrated with the robot or machine) locks the chuck into place. |
| STEP 5. | Machining: The machining center performs the designated end mill processing. |
| STEP 6. | Unlocking: The electric screw tool releases the chuck lock. |
| STEP 7. | Unloading: The robot picks the finished processed part from the machine. |
| STEP 8. | Stacking: The robot places the finished part back into its original position on the pallet. |
| STEP 9. | Indexing: Once a row on the pallet is complete, the system rotates or shifts the pallet to prepare for the next set of workpieces. |
Features
Maximizing Flexibility through Human-Robot Collaboration
Optimized Division of Labor: The robot continuously performs strenuous or repetitive tasks, while the human operator manages the overall workflow between pre- and post-processing stages, significantly increasing system efficiency.
Easy Work Teaching
Direct Teaching: Operators can teach new points simply by manually moving the robot arm.
Compliance Control via Torque Sensors: Utilizing high-sensitivity torque sensors, the robot can perform "soft" contact tasks, ensuring workpieces are perfectly seated flush against the chuck.
Rapid Changeovers: Even when part models change, additional teaching can be completed within 10 minutes, ensuring minimal production downtime.
Enhanced Operational Safety
Omnidirectional Sensitivity: High-resolution torque sensors (0.2Nm) are mounted 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 logic during picking and unloading to react softly to external forces, minimizing potential impact on both the robot and the workpiece.
Compact Installation
Space Efficiency: The compact design of the collaborative robot minimizes the physical footprint required for installation, allowing it to fit into existing factory layouts without major modifications.
Results
| Key Benefits | Improved operational efficiency by allowing existing workers to take on additional high-value tasks.
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| Client Feedback | For products with long machining times, having a worker wait constantly was highly inefficient. Now, the robot handles the machining cycles, and the operator only needs to periodically exchange pallets. This has drastically boosted our overall labor productivity. |
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