Bridge box parts are known for their high precision, complex geometry, numerous machining steps, and heavy weight. To enhance both processing accuracy and production efficiency, many heavy-duty automobile manufacturers have turned to CNC machining centers for these components. When using a CNC machining center, the workpiece must be precisely positioned on the table, and consistent feeding is essential. However, traditional manual loading methods suffer from high labor intensity and limited precision control, leading to a gradual shift toward industrial robots or specialized machines.
Industrial robots offer exceptional repeatability, reliability, flexibility, and automation, making them ideal for modern manufacturing. Compared to human labor, they significantly boost productivity and product quality. In contrast to dedicated machines, they provide greater flexibility with lower investment costs. As a key part of the reducer housing production process, robot-based intelligent handling systems have been successfully implemented in domestic heavy-duty truck factories, though their adoption remains limited across China.
With the rapid development of the national economy, the production capacity and efficiency of heavy-duty trucks need to evolve significantly. Industrial robots serve as powerful tools for this transformation, offering promising market potential.
Site layout
Project Description
The system uses one robot to manage the loading and unloading of five machine tools. Here’s how it works:
(1) One FANUC R-2000iB / 165F robot is mounted on a linear axis, enabling efficient loading and unloading across the entire system.
(2) A custom robotic gripper, designed specifically for the robot, is ideal for handling workpieces with inconsistent shapes. It offers high positioning accuracy, strong grip stability, durability, and easy maintenance.
Claw
(3) A 11-meter-long walking axis allows the robot to move at a maximum speed of 1.5 m/s, driven by a FANUC servo motor. The system features high repeatability, fast response, and stable operation. A specially designed dust cover protects moving parts like guide rails and linear bearings, increasing system reliability and lifespan.
Walking axis
(4) Two loading and unloading slides each hold four pallets, allowing storage of one workpiece per pallet. Thanks to visual technology, no mechanical positioning devices are needed for the workpieces.
(5) The FANUC iR Vision 2DV system uses a 2D camera to capture visual data, enabling accurate grasping of the workpiece. This eliminates the need for mechanical pre-positioning fixtures, offering high flexibility for mixed product production in the machining center.
(6) The FANUC iR Vision 3DL system uses a 3D laser sensor to detect changes in workpiece positioning. Since the workpieces are raw materials, their positioning holes and flatness may vary after being picked up. This system compensates automatically for such changes, ensuring precise loading.
3DL vision bracket
(7) Five sampling slides are used, one for each machine tool, to monitor workpiece quality in real time.
(8) The electrical control system includes a man-machine interface for monitoring the system's operation. A Mitsubishi Q-series PLC controller manages real-time and non-real-time data transmission via an industrial fieldbus, ensuring high reliability and ease of maintenance. Safety features, such as door switches, isolate the robot's working area, ensuring personnel safety during automated operations.
This advanced equipment greatly enhances product quality consistency, reduces labor demand, boosts automation levels, lowers operational costs, and strengthens the company’s competitive edge in the market.
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