Process layout
This automation solution utilizes the Doosan M1013 collaborative robot to automatically load and stack powder-compacted cutting tool components onto pallets. This system is characterized by its rapid teaching capabilities and high workplace safety.
The powder compaction process traditionally generates significant amounts of dust, creating a hazardous environment for human workers. By implementing robot automation, idle time has been minimized to allow for continuous operation. Furthermore, a 100% inspection process has been integrated into the workflow, successfully reducing the overall defect rate.
Components
| Robot |
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Workflow
| STEP 1. | Picking: The robot picks the finished product after the press forming process is complete. |
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| STEP 2. | Cleaning: The product is placed into an air-blowing device to remove residual powder and dust. |
| STEP 3. | Inspection: The robot unloads the product onto a scale to measure weight and determine if it meets quality standards (Pass/Fail). |
| STEP 4. | Error Handling: If a defect is detected, the system triggers an alarm for operator notification. |
| STEP 5. | Stacking: High-quality products are accurately unloaded and stacked onto the discharge pallet. |
Features
Improved Production Efficiency and Quality
Continuous Operation: Minimizes idle time through seamless task execution, significantly boosting production efficiency.
100% Inspection: Integrates automated weighing and inspection to minimize defect rates and ensure consistent quality.
Safe Working Environment
Dust Hazard Mitigation: Eliminates human exposure to the fine, hazardous dust generated during the powder compaction process.
Easy Work Teaching
Direct Teaching: Allows operators to set up and adjust points intuitively by manually moving the robot arm.
Compliance Control via Torque Sensors: Enables high-precision handling, ensuring parts are perfectly aligned with fixtures or jigs through sensitive force feedback.
Rapid Changeovers: Facilitates model changes with additional teaching completed in under 10 minutes.
Enhanced Operational Safety
Omnidirectional Sensitivity: High-resolution torque sensors (0.2Nm) on all 6 axes allow the robot to detect and react to the slightest collisions from any direction.
Shock-Minimizing Logic: Applies compliance control during picking and unloading to react softly to external forces, protecting both the robot and fragile "green" compacts.
Compact Installation
Space Optimization: The collaborative robot’s small footprint allows for easy integration into existing lines without the need for large safety enclosures.
Results
| Key Benefits | Improved workplace environment (Removal of hazardous dust-related labor).
Enhanced defect detection and response through integrated 100% inspection. |
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| Client Feedback | Our workers had to wear masks constantly due to fine dust, making this a highly avoided task. By automating the process and adding 100% inspection, we improved both productivity and quality simultaneously.
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