Automated Workpiece Loading & Unloading System for Automotive Parts Machining Lines

#MachineTending#WorkpieceHandling#RoboticLoading#RoboticUnloading#MachiningAutomation#KawasakiRobot#InfeedOutfeedConveyor#AutomotiveManufacturing

Process Overview

This solution enables automatic loading of workpieces into machining equipment, including irregular, non-standard workpieces generated from hot forging, by using a specially designed gripping tool in the automotive parts machining load/unload process.

Developed through the company’s in-house R&D, this automation system uses a custom-made gripper to automatically load hot-forged workpieces, even those with inconsistent shapes, into the machining area.

Components

Robot	KAWASAKI CX210L: 6-axis industrial robot, payload 210 kg, max reach 2,699 mm, weight 870 kg, repeatability ±0.06 mm
Peripherals	Gripper Infeed conveyor Outfeed conveyor Inspection unit Rust prevention unit

Workflow

STEP 1.	Operator loads workpieces onto the infeed conveyor
STEP 2.	Robot loads workpieces into the machining center
STEP 3.	Machining completed
STEP 4.	Robot unloads finished parts from the machine
STEP 5.	Automated inspection
STEP 6.	Robot loads finished parts into the rust prevention unit
STEP 7.	Robot transfers finished parts from the rust prevention unit to the conveyor

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Key Features

Increase productivity and resolve issues in existing automation

Enables automatic loading of large hot-forged workpieces into the machining center without defect sorting
Secures high productivity through continuous operation with minimal downtime
Addresses labor shortage issues by mechanizing physically demanding tasks (loading heavy workpieces over 12 kg into machining equipment)

Implementation Results

ROI Period	1 year
Key Metrics	Improved working environment and labor conditions No need to sort good vs. defective parts before loading into the machining center
Client Feedback	By enabling automatic loading into the machining center without defect sorting for large hot-forged workpieces, the system reduced unit costs and increased production output.