High-precision machine loading: automated (un)loading of a press machine

Challenge

The goal of this metalworking company was to increase the output of one of their product lines. To achieve this goal, they wanted to improve the machine loading and unloading process of one of its press machines. This press flattens custom-made round metal rods into a particular shape to make them more aerodynamic.

Their previous machine loading process had two major downsides.

It was too slow. The production line could not keep up with client demand.
The positioning of the rods was not precise enough. This compromised product quality and even led to product loss.

The challenge of this automation was a hard to handle shape in combination with pinpoint accuracy. On top of that, we had to guarantee that high precision for various rod sizes.

Solution

We designed and built a machine loading system for their existing press machine.

The operator can now bulk feed the press machine. No longer one rod at a time, but large quantities at once.

With a custom designed and built chute system, we separate the rods before they go onto the conveyor belt, one by one. Here two little springs, each at one side, firmly grab hold of the rod.

Each rod carries a marker: a smiley-like symbol. This acts as a reference point for the camera system we integrated. This camera checks the positioning and then transfers that data to the turning unit.

This unit then adjusts the rod accordingly, so it’s positioned just right into the mould of the press machine.

After a final check, the rod is then loaded into the press machine.

The operator can adjust the width of the machine, so the machine is able to handle different rod lengths. He can do so manually with a spinner wheel.

Results

A machine loading system that places rods of various lengths into the mould of a pressing machine with great precision. And by doing so, improves product quality and increases output.