Process layout
This assembly automation solution utilizes five Doosan M0609 collaborative robots to fully automate the end-to-end assembly process of faucets.
Previously, this process required a large number of workers to manually assemble each unit. By integrating collaborative robots with a conveyor system, continuous production across the entire process has been achieved.
The transition from a manual line (where 5 workers produced 1,000 units per day) to an automated line (where 2 workers produce 1,200 units per day) has resulted in a significant improvement in productivity.
Components
| Robot |
|
|---|
Workflow
| STEP 1. | Assembly of the faucet diverter valve plug (Robot 1). |
|---|---|
| STEP 2. | Loading the hot/cold water pipe connection plugs into the screw fastener (Robot 2). |
| STEP 3. | Assembly of the hot/cold water connection nuts onto the faucet. |
| STEP 4. | Insertion of the flow control valve (Robot 3). |
| STEP 5. | Insertion of the flow control valve retaining nut (Robot 3). |
| STEP 6. | Tightening of the flow control valve retaining nut. |
| STEP 7. | Flow control leakage testing. |
| STEP 8. | Insertion of the flow control handle. |
| STEP 9. | Insertion of the flow control handle fixing pin. |
| STEP 10. | Completion of assembly and discharge. |
Features
Improved Production Efficiency and Quality
Continuous Operation: Maximizes production efficiency by performing seamless, non-stop tasks with minimal idle time.
100% Inspection: Minimizes defect rates by integrating automated quality checks throughout the process.
Labor Optimization: Reduced the required manpower from 5 workers to 2 by minimizing management overhead.
Enhanced Operational Safety
Omnidirectional Sensitivity: High-resolution torque sensors (0.2Nm) on all 6 axes allow the robots to detect and react to subtle collisions from any direction, ensuring worker safety.
Shock-Minimizing Logic: Applies compliance control during picking and unloading to react softly to external forces, protecting delicate faucet finishes.
Compact Installation
Space Efficiency: Utilizes the compact design of collaborative robots to minimize the footprint; the entire automated line occupies only 2m x 6m.
Easy Work Teaching
Direct Teaching: Operators can teach points intuitively by manually moving the robot arms.
Precision Handling: Compliance control via torque sensors allows the robots to perform "soft" tasks like inserting and pushing components with the appropriate force.
Results
| Key Benefits | Before: 5 workers produced ~1,000 units/day (200 units per person).
After: 2 workers produce 1,200 units/day (600 units per person).
|
|---|---|
| Client Feedback | As customer demand grew and requirements became more diverse, our process steps and workload increased. By automating the continuous mass-production stages with cobots, we’ve boosted productivity enough to meet the rising demand. |
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