Brake pad packing

Implementation context

When several hundred products pass through the production line, the selection and packaging operations pose a challenge for operators. Choosing the right element from the tape, or the pace at which you need to perform such an operation requires the employee to be constantly focused and accurate in their activities, not to mention that all these activities must be carried out as soon as possible, so as not to cause downtime or delay in production.
Robots, whether they choose a specific element indicated to them or just another one available, can perform these tasks without rest and maintaining much greater work efficiency in relation to humans. Additionally, using specialized, dedicated software, you can coordinate the work of machines and once again increase its efficiency. This will not only save valuable time, but also reduce the cost of production relative to its implementation through operations performed by employees.

Cooperation and implementation

Due to the nature and arrangement of the production hall, the collective belt conveyor, which was previously operated by employees, was given various models of brake pads. In many cases, the differences between the models are small, but important details, such as the shape, the presence of components or small differences in dimensions. In a situation where the employee has a little less than 5 seconds to analyze and assign to a specific model, the risk of error is high, and making decisions does not facilitate the constant movement of products on the conveyor.

In the presented situation, the use of a sorting robot will allow precise identification of the object based on visual identification available thanks to the use of high-class sensors. Additionally, by using an automated solution, it is possible to sort and move brake pads faster. The average time a robot needs for correct identification and transfer is less than 2 seconds, which, taking into account the current production rate, means that only 2 machines are required to fully automate this production segment.

Benefits

  • The technology of visual line tracking allows you to coordinate the work of up to four robots, so that they can use the vision system to carry out the process of sorting and picking elements arranged randomly on a moving conveyor belt, with an accuracy significantly exceeding human capabilities.
  • The robots are specially adapted to work in environments that must meet certain conditions. This allows not only to obtain the highest possible quality of products, but also not to degrade it at a later stage of production by improper transport or storage.
  • The supplied tracking virtualization software enables the simulation of visual tracking systems using multiple robots before they are installed in a real production system. It also allows ongoing monitoring of the work of sorting robots and possible configuration of its parameters in real time without stopping production.
  • Coordinated robots can handle up to 3,600 transfer operations, using intelligent monitoring systems are able to balance flow in a given direction, or remove elements in which a defect has been potentially detected in the production process.