Superiority
Superiority
Project
workpiace
automation-video
Workpiece:gas accessory

M Company :A factory in Miaoli, Taiwan Planning date :June, 2014

Content

Technical solution: multi-axes robot with CNC lathe automation workstation
The equipment supplied :
CNC  lathe x 2 , multi-axes robot x 1 , flat feeding device , customized jaw x 1
Proposed solution:
After careful planning, the proposed L-shaped configuration mining CNC lathes, multi-axis robot center placed sequentially carried turning.

Processing steps:
Robot arm to feeding device, gripping workpiece A to be machined by CNC lathe → machined  workpiece A →workpiece A processing is completed, robot gripping A return to
feeding device,and Gripping unfinished workpiece to CNC lathe to be machined →workpiece B machining is completed, the robot gripping returned to the feeding device,and
then the other gripping the workpiece to be machined to the lathe.

Expected effect :

● Reduce labor costs 48%, improve production efficiency of 63%

 
workpiace
automation-video
automation-video
Workpiece:fast plug

M Company :A factory in Taoyuan, Taiwan Planning date :July, 2014

Content

Technical solution:Gantry type with CNC lathe automation workstation
The equipment supplied :
CNC lathe x 2 , 1vs1 gantry  type  robot , flat type feeding device , customized jaws x 2
Proposed solution:
After careful planning, we proposed stand-alone configuration
Through gantry type robot gripping workpieces, according to the finished product, unfinished finished workpiece sequentially take turns by lathe .
Processing step :
Mechanical arm gripping the workpiece to be machined (A & B) to the lathe for processing →A workpiece turning completed, the robot gripping finished workpiece to be
machined replacement B →processing  B workpiece →robot gripping the finished piece A back to the feeding device while gripping the workpiece to be machined →
B workpiece machining is completed, the robot gripping finished, replacement workpiece to be machined.

Expected effect :

● Reduce labor costs 52%, improve production efficiency of 36%

 
workpiace
automation-video
Workpiece: motorcycle crown base【Braect】

M Company :Motorcycle parts' manufacturer in Indonesia Planning date :2013.08
Existing processing method:
feeding and blanking manually by the operators on duty up to 55 persons who work by 3 shifts. The average capacity is 200 pcs per day and the yield is about 90%.

Content

Technical solution: multi-axis robot automation work station
The equipment supplied :
CNC vertical machine center x 3, multi-axis robot x 1, the 4th axis rotary table x 3, customized special gauge x 3.
Proposed solution:
The machines equipped with hydraulic fixture are suggested being placed as triangle. The multi-axis robot automatically processes the feeding and blanking in clockwise to save the processing time.
OP1: To mill, punch holes and chamfer the workpiece by a vertical milling machine with special gauge
OP2: Carry the workpiece finished processing to the rest 2 milling machines by the robot, and then combine with the 4th axis rotary table and hydraulic gauge to process the other three sides.

Expected effect :

● the operators on duty down to 23 persons and the labour cost reduce by 58%
● the capacity promote up to 290 pcs per day which is 45%
● the modular processing yield improve to 95%

 
automation-video
automation-video
Workpiece: Lower housing

Y company : motorcycle parts' manufacturer in the north of TaiwanPlanning date:2013.10
Existing processing method :
1. Operators work by 3 shifts for 24 hours. When staff rest, the machines have to stop working.
2. Feeding and blanking by manpower make the precision unstable.
3. The machine maintenance time plus the staff break time is about 6.5 hours which is unable to reach the man-hour standard.

Technical solution A: 1 to 4 gantry robot automation production line

The equipment supplied:
MACHTEK CNC lathe TC-210, SINATEK automation cantilever type robot (SGD series), bar type feeding table
Proposed solution:
The machines are suggested being placed in two lines and dispose each line with two milling machines. The 4 milling machines combining with the gantry robot to be the production line which can feed and blank automatically and mill simultaneously. The staff on duty can tour the processing in the middle aisle, supply the materials if needed, and the QC can inspect the processing as well.

Technical solution B: small gantry circle feeding and blanking automation production line

The equipment supplied:
MACHTEK CNC lathe TC-210, SINATEK automation build-in gantry robot, lifting feeding table
Proposed solution:
A machine combine with the build-in gantry robot to be the work station. Based on the environment, we place 4-6 sets of the automation work station and each station can feed and blank automatically and mill simultaneously. The staff on duty can tour the processing in the aisles, supply the materials if needed, and the QC can inspect the processing as well.

Expected effect:

● Automatical feeding and blanking not only ensures the stability, saves the reloading time but also solves the single tray problem . The machines can still work when the staff rest, which effectively improve the processing time and the capacity.
● Save the labour cost. There are about 1-2 employees who is responsible for each production line. Only 2-4 employees need to be on duty every day.
● Modular design for the machine, robot and the feeding table saves the maintenance time.

 
workpiace
automation-video
Workpiece: bicycle hub

M company : bicycle parts' manufacturer in the middle of TaiwanPlanning date:2013.02
Existing processing method:
1. Milling and turning are separated. There are 5-7 employees on 2 shifts duty in each production line.
2. Feeding and blanking by manpower make the precision unstable.
3. The machine maintenance time plus the staff break time is about 8 hours which is unable to reach the man-hour standard.

Content

Technical solution:turning and milling automation station of bicycle hubs
The equipment supplied :
MACHTEK CNC lathe TC-210 x 1, vertical milling machine V-500L x 1, Fanuc multi-axis robot x 1, flat plate feeding table x 1
Proposed solution:
1. CNC lathe and milling machine are suggested being placed by L type, and place the multi-axis robot in the middle. The manufacturing order in turn will be turning and then drilling and milling.
2. Specification of manufacturing procedure:
I. The jaw of the robot works first,
II. The jaw places the forging blank of the hubs.
III. OP1: turning the OD of the hubs by CNC lathe.
IV. OP2, the jaw picks up the workpiece for milling.
V. Combine the high speed machining center and the CNC lathe which makes it become an automation production line.
VI. OP2: the jaw lays the hubs and starts to milling.
VII. OP2: drill arbor hole, bearing hole, milling lightening hole and drill steel wire hole.
3. The placement is convenient for the staff to tour the processing condition and supply the materials if needed. Besides, the QC can inspect as well.

Expected effect

● A staff member can on duty for 2-3 sets of work station which saves the feeding and blanking time.
● Feeding and blanking precisely improves the stability of machining accuracy effectively.
● The area of the work station is smaller. Modular design of the robot and the feeding table is good for the stabilization of the man-hour.

 
automation-video
Workpiece: motor end cover

Z company : Motor manufacturer in the south of TaiwanPlanning date:2013.01
Existing processing method:
1. The three processing methods, casting, punching and turning, are in three districts which is inconvenient and inefficient.
2. Each processing method needs 2-3 employees on duty. Three kinds of machines need 7-9 employees.
3. It is inadequate of the capacity and wastes of space and time.

Content

Technical solution:casting, punching and turning automation production line of motor end cover
The equipment supplied :350T die-casting machine, multi-axis robot x 1, CNC punching machine, CNC lathe, conveyor belt.
Proposed solution:
1. CNC punching machine and CNC lathe are suggested being placed in a line. Besides, the die-casting machine will be placed in another line, and the multi-axis robot is in the middle to connect all the machines.
2. The rough blank after casting is picked up by the multi-axis robot, and then cool it and carry it to the punching machine to punch it.
3. When punching the blank, the robot changes the jaw and carries the workpiece finished punching to the lathe to turn. In the end, carry the finished products to the inspection station by the conveyor belt.

Expected effect

● Systematic designed production line saves the space and smooth processing.
● Only need 3-4 employees on duty which saves the labour cost by 75%.
● Pick, cooling, punching and turning are all in sequence and the processing instruction design makes it easy to operate and stabilize capacity and man-hour.

 
workpiace
automation-video
Workpiece : truck's piston

S company : Truck's piston manufacturer in the south of Taiwan Planning date:2013.06
Existing processing method:
trimming by hand causes spotty quality of finished workpiece or misses grinding some part of the workpiece. In the end, the quality of the finished workpiece isn't stable.

Content

Technical solution:trimming the piston by automation robot
The equipment supplied:multi-axis robot x 1, fixture gauge.
Proposed solution:
1. To assure the quality, we suggest grinding by multi-axis robot with high speed spindle.
2. Based on the shape of the workpiece to grind the parts need trimming will effectively achieve good quality result.

Expected effect

● Grinding by one machine saves the space.
● Stable grinding quality makes accurate of the capacity and improves it by 65%.
● Operation instructed design and easy to operate.

 
Workpiece : automobile parts

S company : Japanese automobile parts' manufacturer in the southeast AsiaPlanning date:2012.11
Existing processing method:
1.When processing, 2-3 employees need to be on duty. Besides, 4-6 employees are responsible for 2 machines.
2.feeding and blanking by hand is low efficiency and low productivity.

Content

Technical solution:automation feeding and blanking production line
The equipment supplied:
1 to 2 gantry robot (SGD series), special 3-axis jaw, customized the 4th axis reversal fixture, rotary flat feeding table, vertical machine center V-1000L
Proposed solution:
1. We suggest processing by 1 to 2 gantry robot with customized fixture.
Specification of the procedure :
I. Operate by the robot jaw
II. the C axis of the robot reverses
III. feeding by the automation hydraulic gauge
IV. the 4th axis fixture reverses and blows
V. face milling
VI. drilling.

Expected effect:

● Automation feeding and blanking saves the work time and makes the product yield improve to 15%.
● Save the labour. The operators improve from 1-2 employees operate 1 machine to a staff member operates 2-3 machines. The labour cost reduces by 42%
● Automation feeding makes the productivity improve by 20%.

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