Case Study | ALSONTECH Automatic Castings Loading Solution

2022-12-08 10:07

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Project Background

In orderto improve the efficiency and yield of machining, a well-known auto partsmanufacturer intelligently upgraded the workstation, and used robots tocomplete the automatic assembly and loading of a variety of caliper shells,push plates and other workpieces.

Pain Points

§AGV or forklift transports the pallet loaded withthe workpiece to the loading area, the ground is only simple discharge zonedivision, and the precise limit device is not installed, the ordinary pallet istransferred, and the workpiece will be displaced in the process, so it is notpossible to complete accurate loading by robot teaching alone in the loadingarea;

§The workpiece is pure black casting, and the typesvary from 1~3 kinds according to the production needs, which need to beaccurately identified visually and flexibly switched in a variety of materials;

§After loading a pallet of workpieces, the visionneeds to identify the empty pallet.

Solution

According to the layout of the site, the loadingprocess, the beat and other requirements, finally choose AT-S1000-06C-S 3D vision system for the user, the 3D vision camera arm is installed on the end axisof the robot, and its real-time spatial coordinates are sent to the robotthrough the scanning of the incoming workpiece, and the robot is guided toaccurately grasp and complete the loading.

AT-S1000-06C-S 3D vision camera has thecharacteristics of high precisionandhigh beat,and cooperates with therobot to achieve the customer's requirements forcomprehensive positioningaccuracy of not less than ±0.5mm. The upgradedblue light technologyis used to effectivelycope with the environmental complexity of open workstations, and has high recognition rateand recognition accuracy for darkcolors, especially pure black workpieces, and can obtainhigh-quality and effective point clouds, and cooperate with self-developed pointcloud processing algorithms to help projects land quickly.

User Benefits

§   Efficiency and Cost:

o The workpiece is a casting, the monomer has acertain weight, the overall labor intensity of manual repeated handling and loadingis large, at least 2 people/groups are required to work in shifts to meet theproduction, the machine substitution overcomes the problem of labor intensity,3D vision solves the problem of intelligent and precise positioning, ensuresthat the robot can operate continuously according to production needs, and the loading efficiency is guaranteed and improved;

o In terms of workstation design, there is no need tocustomize multiple sets of tooling, no need to install ground in placerestriction devices, no need to customize a variety of acupuncture points/cardslot trays, the 3D vision system can increase different types of workpieceswithout limit and quickly complete category switching, reduce the time ofmanual replacement of tooling and pallets, avoid tooling waste caused bycategory changes and material stoppages, and greatly reduce the input cost and maintenance cost of fixed facilitiesat the station.

§ Security:

o ALSONTECH's supporting software platform contains avariety of grasping strategies, such as when grasping the caliper shell, due tothe holes on both sides of the gripper shell, the workpiece is placed closely,and the sliding during the transfer is close to each other, etc., the 3D visionsystem protects the workpiece and fixture while ensuring effective grasping andloading through reasonable obstacle avoidance settings;

o Manual repeated handling of heavy workpieces,monotonous, boring, there is a certain risk of work injury, 3D vision system toguide robots to replace manual work, can also effectively avoid the risk ofwork injury.