Robotic Cells for Planetary Gear Handling
Need
New Manufacturing Line
Volvo Construction Equipment needed a complete overhaul of an existing manufacturing line for planet gears and sun gears due to capacity reasons.
The manufacturing line produces planet and sun gears, from raw material to finished part before hardening.
The overhaul required new automation equipment for the various processes.
A new method for packaging finished parts directly onto hardening fixtures.
Solution
Robotic Automation
The solution consists of three parts: handling to milling machines, deburring cell, and packing on hardening fixtures (line packing).
Handling to Milling Machines
- Three overhead-mounted ABB robots pick products from the conveyor to the machine.
- A pallet conveyor circulates products between machines and for loading and unloading.
- The cells include centrifuges for drip-free parts after the operation.
- A marking station for product marking is included.
Deburring Cell Handling
- Traditional robot cell with pick-and-place from conveyor to machine.
- Centrifuge: motor-driven centrifuge for removing chips and processing fluids.
Line Packing
- Robot: ABB robot type IRB6400-185/2.8 with pneumatic gripper.
- Pallet racks: Two pallet racks, each with an in-pallet and out-pallet, for loading and unloading gears from the cell.
- Vision system: Cognex vision system for locating parts in the pallet.
- Vision system: Cognex for inspecting parts.
- Turning station: Turns gears that are incorrectly positioned in the pallet.
- Intermediate station: Rack with two shelves for intermediates.
- Reject station: Station for removing gears for inspection or rejection.
- Vacuum gripper: Used by the robot for handling intermediates.
Facts
| Customer | Volvo Construction Equipment |
|---|---|
| Production Start | 2007 |
| Industry | Automotive |
| Managed Product | Gears, Sun Gears |
| Product Size | Diameter 90-180 mm |
| Product Weight | 1-15 kg |
| Cycle Time | 40 seconds |
| Serial Number | 0681 |
Result
We, as the customer, find the machine to be very user-friendly despite its complexity.
The result exceeded the customer's expectations, as the controlled approach allowed for additional volume increases in the factory beyond what was originally planned.
The equipment has been in production since 2008.
"We, as the customer, find the machine to be very user-friendly despite its complexity. Normally, you would need to call in a robot supplier to make any changes, but first of all, we have had very few problems, and on the occasions when we did need help, Sejfo provided excellent phone support and resolved the issue quickly." – Marcus Tsingos, Volvo CE
