Robotic Success Stories
Productivity’s Success Stories provides applications of various robotic automation systems for manufacturing companies. Download brochure here.
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OEM Pump Manufacturing
We provided a complete production solution to this customer, which replaced more than fifty traditional machine tools, that were combined into seven different production cells. This reduced floor space requirements, part cycle time, work in process, and improved part quality. Changeover of the automation is done by selecting a different part number from the cell control’s HMI touch panel. One half of this cell can be in automatic operation while the other half is being changed over to a different part.
Medical Parts Processing
This custom system runs with one operator who primarily attends the tooling and turning process details. Raw bar stock is loaded into the 4 CNC Swiss-style turning centers where the part process is performed, while the robotic portion handles the remainder of the process. Complete parts that are ready for final inspection, reporting, and packaging are delivered to the cell operator on custom trays. Complete part traceability is achieved.
RoboFlex® Flexible Handling System
RoboFlex® VP is a self-contained and limited machine tending system. It costs under $100,000 and can be installed in a 4′ x 7′ space. It can front load or side load smaller VMCs and can be shipped assembled and ready to position within reach of machine loading area.
Adding Machining Capacity
RoboFlex® CS is a larger complete machine loading system. It can tend two machines from one robot. Easy to changeover. Vision system can rapidly locate work pieces and guide the robot to where the parts actually are. No special locating templates are required. Material can be replenished while machines are in operation.
The system that we provided to this manufacturer allows complete machining of this part with no machine operator present. The system, when fully loaded, will run for 12-14 hours. It takes about an hour to unload, replenish, and service the machine. This can mostly be done while the equipment is in operation. Provisions were built in originally to
allow a second machine and robot to this system which will allow twice as much output from the system without modifying the pallet transfer equipment.
Flexible Multiple Cell Operation
The system we supplied manufactures four part numbers simultaneously, starting from bar stock to bin packing, with the part time attendance of an operator. Raw stock is loaded into the cold saw and cut to proper length. A robot unloads saw and loads a four-lane conveyor, which conveys cut stock to each of four, two VMC machine cells. Each cell
consists of an OP10 VMC, a OP20 VMC and a robot between both VMCs. When manifolds are machined complete, the robot places manifolds onto the four-lane conveyor and conveys parts to pin marking and bin loading. A packing robot at the end, stamps
the part ID and loads it into wooden crates.
High Accuracy / Volume Manufacturing
The system that we provided to this manufacturer allows complete machining of this part with no machine operator present. The system, when fully loaded, will run for 4-5 hours. It takes about an hour to unload, replenish, and service the machine. This can
mostly be done while the equipment is in operation. The simple single nest fixture has replaceable nests for quick and easy part changeover. Standard machine and fewer mechanical components allow high machine uptime, and better part quality.
Random Part/Pallet Processing
The system that we provided allows flexible operation and the ability to easily add new parts to this system.
The part pallets/fixtures have unique RFID tags embedded into them, allowing the VMC CNC control to automatically change part programs when robot passes the pallet by the RFID scanner. This allows the system to run a large number of parts with little or no
Custom robotic system to transfer parts from handling racks into the overhead line that feeds a group of production machines. Custom End of Arm Tool to handle individual part patterns, as well as individual trays, that are all carried by an overhead part transport system.
Custom Non-CNC Industrial Equipment
A custom Laser Class 1 enclosure that contains a FOBA marking laser, a FANUC robot, and raw material drawer shelves in one compact footprint. A barcode scanner was integrated in this cell so the marking operator can scan the customized text strings directly from the part routing rather than keying in the “custom” marking requested by the order packet.
One-Up Machining vs Mutli-Palletization
By changing to one-up from multi-palletization, Alliant Techsystems Inc. (ATK) would reap a significant cost savings, in addition to lower initial cost of the equipment. Additionally, the lights out machining advantages would reduce part production cost by nearly 50 percent. It was clear that not only would it be cheaper to go one-up, but by the end of the day the company would produce more parts.