Automated Forming Workstation with Cobot
Identified Issue:
The client, operating in the automotive components sector, needed to validate its forming process more rigorously.
The main production challenges concerned processing accuracy, result repeatability throughout the entire cycle, and the high incidence of manual interventions, which slowed down the production flow and compromised overall efficiency.
In addition, the project had to comply with stringent design constraints: limited space, tight delivery schedules, and high technical requirements, in line with the quality standards imposed by the international automotive market.
Implemented Solution:
Opus automazione tackled the challenge starting with a manual testing phase on samples, aimed at identifying the most effective process parameters. From there, the complete mechanical and electrical design of the workstation began.
The intervention included:
Development of a compact and functional structure
Complete wiring and assembly carried out in our laboratories
Integration of a collaborative robot (cobot) to automate operations
Development of the control software and management of the operating cycle
All components were tested and commissioned by our specialized team, which validated the system directly in a simulated environment.
Software and Integration:
The core of the automation lies in the internally developed software for managing the drives and the collaborative robot. Thanks to custom programming, the system ensures precision, safety, and adaptability.
The use of the cobot added significant value, enabling safe interaction with operators and greater operational flexibility. The simple and intuitive control interface allows for quick process adjustments based on production needs.
Results Achieved:
The introduction of the automated workstation delivered tangible results:
Cycle time reduction of up to 35%
Scrap reduction to below 2%
Increased overall process reliability
Significant reduction in routine maintenance
Improved uptime and operating costs
These benefits enabled the client to make their facility more competitive, increasing both productivity and quality.
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