WaterJet Case Study - Tech-Con Automation
Robotic Palletizing solutions case study by Tech-Con Automation
Palletizing Solutions
584
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WaterJet Case Study

An automotive carpet manufacturer required a fast and accurate method to cut flooring material that reduced waste. Tech-Con Automation developed a solution using four Motoman HP-20 robots, fi tted with UHP hardware, to meet the customer’s production and product quality needs.

Customer Needs

    • Operator interaction: The nature of the product made it difficult to mechanically move it into and out of the cell. Operators had to be able to access the cell to lay and remove carpet to and from a 3D fixture.
    • Speed of cutting: Because of operator interaction, the cycle time had to be reduced as much as possible.
    • Limiting waste: The cutting process could not damage the carpet.
    • Holding the carpet in place: The method used to hold the product in place could damage the pile and affect product quality.

 

Our Solution

    • Automate the stacking process: The Tech-Con team decided to use a robot to load and unload the product. Inverting the robots eliminated floor-space clutter and enabled the operators to access the carpet without weaving around the robots.
    • A “safe position” was programmed to de-activate the robots and keep them out of the operators’ way.
    • The cell cycle time was too short for one robot to complete the length of cut around the perimeter so Tech-Con developed a solution with four robots cutting simultaneously without damaging the carpet or interfering with each other. What’s more, a better quality cut was achieved by slowing down the cutting speed of each robot.
    • Waterjet cutting tool: The use of high pressure water for cutting produces the exact profile, eliminates damage to the carpet, and the need for tool sharpening.
    • Vacuum suction: By developing a suction tank integrated with the cutting fixture, the carpet was held down by negative pressure. Water naturally falls into the tank and excess carpet bits are retrieved the same way, by filtering the re-circulated water.

 

Benefits

    • Productivity & Quality: High-speed cutting with four inverted robots reduced cycle times and increased production and, with the new system, neither cutting nor handling damaged the carpet.
Date
Category
Waterjet