Process layout
This machine tending automation solution utilizes the Neuromeka Indy7 collaborative robot (cobot) to automate the manual process of handling graphite electrodes in a machining center (MCT).
By integrating pre-process data entry, real-time monitoring, and actual measurement tasks, the system ensures high-precision machining. Workers are now only responsible for loading raw materials into the feeding section, while the robot handles the actual machining operations. This shift allows a single operator to manage and operate multiple machines simultaneously, significantly boosting both production efficiency and quality.
Furthermore, by leveraging Gun Solution's specialized integration, the robot can perform tasks in the same manner as a human operator even on older legacy machine tools. This eliminates the need for expensive hardware interfaces, resulting in substantial cost savings.
Components
| Robot |
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Workflow
| STEP 1. | Place raw materials into the pallet. |
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| STEP 2. | Select the material for processing. |
| STEP 3. | Input material information (via QR code & automated Vernier caliper measurement). |
| STEP 4. | Transmit machining data to the Machining Center (MCT). |
| STEP 5. | Execute robot program. |
| STEP 6. | Push the Cycle Start switch. |
| STEP 7. | Clean the jig inside the MCT. |
| STEP 8. | Pick up the raw material. |
| STEP 9. | Load the material into the machine. |
| STEP 10. | Probe measurement of the workpiece (Reject if "NG" / Not Good). |
| STEP 11. | Machining. |
| STEP 12. | Air-blow cleaning of the finished part. |
| STEP 13. | Pick up the finished part. |
| STEP 14. | Unload the part back to its original position on the pallet. |
Features
Quality Assurance & Easy Operation Monitoring
Multi-stage Verification: Ensures high-quality standards through a double/triple check and inspection process.
Traceability: Easy to track work history and results, allowing for precise root-cause analysis of any defects.
Maximized Flexibility & Compact Installation through Collaboration
Human-Robot Collaboration: Efficiency is boosted by having humans manage the overall workflow while the robot performs continuous, repetitive tasks.
Space-Efficient: Utilizes compact collaborative robots (cobots) to minimize the footprint required for installation.
Enhanced Safety: Prevents workplace accidents by implementing high-safety cobots that can work alongside humans.
User-Friendly Robot Teaching
Legacy Machine Compatibility: Robots can be taught to perform tasks in the same way humans do, eliminating the need for expensive interfaces even on older machine tools.
Direct Teaching: Supports an intuitive "Direct Teaching" method, allowing users to move the robot arm manually to set positions.
Results
| Key Benefits | Improved quality through 100% inspection and real-time monitoring.
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| Client Feedback | Previously, we struggled with root-cause analysis when quality issues occurred because we didn't have individual tracking for workpieces. Since adopting Gun Solution's system, we can now track and monitor each individual product, making quality management much easier and significantly improving our actual defect rates.
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