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Process layout
This solution is a 'carrier input automation system' installed in a factory producing automotive catalysts, and consists of advanced automation equipment integrating a 6-axis robot, Cartesian robot, 3D Vision, and a transfer unit.
This system Automating the entire process from automatically recognizing and picking up boxes loaded on pallets → feeding carriers into the main conveyor → discharging empty boxes and trays. The purpose is to significantly reduce the burden of repetitive tasks on workers and improve production efficiency and stability.
In particular, to accurately recognize boxes of various heights and 6 types of carrier patterns Dual 3D Vision system The key feature is that it improves work quality and process reliability by applying [this].
Components
| Robot | Hyundai Robotics HDR80L-26 (YS080L) Industrial Robot |
|---|---|
| Peripherals | 3D Vision System (2 units) |
Workflow
| STEP 1. | Pallet input |
|---|---|
| STEP 2. | Box recognition and transfer movement |
| STEP 3. | Carrier main conveyor input |
| STEP 4. | Empty box and tray discharge |
Key Features
✔ Implementation of 'High-speed Carrier Automation' Rarely Seen in Korea
In the field of small catalysts for vehicles Various carrier patterns + high C/T requirements It is a rare case that satisfies both simultaneously.
✔ Dual 3D Vision Based Precision Recognition System
Accurate recognition of box position/pose
Real-time correction even with carrier variation of ±5mm
Securing recognition efficiency even for dark-colored coated products through parameter refinement
✔ Designed to minimize carrier quality degradation
Orthogonal robot-based uniform carrier handling
Stable input of even shaken or warped products
✔ Supports various product types
box heights differ
6 types of carrier patterns
Response to tray shaking and positional instability
✔ SW logic optimization for stable system operation
PLC recipe automatic call
Alarm when production plan is mismatched
Implementation Results
| Key Metrics | Saves 3 personnel per shift
Stable 24-hour operation without break time
Reduced risk of sudden workforce shortages
Reduced cycle time (C/T)
Robot-based assurance of uniform quality
One-pass automation from empty box to tray discharge |
|---|---|
| Client Feedback | This automated carrier input system has been a great help in simultaneously ensuring productivity and stability. In particular, given the nature of the process which requires handling various box heights and carrier patterns, the stable operation of the robot and 3D Vision was our biggest concern however, the actual operation results showed that recognition accuracy and equipment reliability exceeded expectations. Previously, there were difficulties in manpower allocation due to the high difficulty and repetitive nature of the work, but after automation, the workload was significantly reduced, leading to increased employee satisfaction.
In addition, thanks to equipment alarm monitoring via SOLlink, we were able to respond immediately to abnormal situations, significantly reducing line downtime. Now that this project has been successfully stabilized, we have high expectations for expanding the application of the same system to other lines.
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