In order to automate two injection moulding machines, Decuna installed a robot that unloads the parts from the moulds and layers them in a container.

The main advantage of this system compared to robot arms installed on each injection moulding machines is the cost save implied and simplicity. The robot is able to serve simultaneously both machines.

The injection moulding machines communicate with the robot, indicating when the parts are ready to be picked up from the mould.

A part presence check is performed once the plastic parts are picked up, in order to detect any possible error during injection moulding.

The cycle time was estimated with a computer simulation. The simulation also served as a starting point for robot programming.

The video on the left shows an automated production line designed and built by Decuna for a telecommunications equipment manufacturer. The assembly line is completely automated and integrated with a robot. The robot feeds a machine and unloads components, to be used in further operations

One of the projects developed integrates a robot equipped with a pneumatic gripper with two computer vision systems

- the first one corrects position offsets in the plates to be feed in the machine

- the second one controls with a laser beam the thickness of the plates gripped by the robot, so that only one is introduced in the machine.

Decuna delivered and integrated in the production system a palletizer robot for carboard boxes with variable size for an automated warehouse. In the automated warehouse there are multiple references, carboard boxes with different size and weight, containing different items such as small household electric appliances and clothing.

The warehouse had demanding requirements in terms of output rate, which is completely handled by the robot

Therefore, Decuna designed the robot gripping system, versatile and robust, that adapts perfectly to every system reference. The system admits two kinds of pallets: 800x1200 and 1000x1200. The pallet layout depends on the references placed, and the robot can handle even incomplete pallets and pallets with several references.

Our supply included a system to configure the type of references to be picked and palletized, production setup and security systems such as emergency stops and light curtains with muting according to industry standards.

This robot applies weling paste for automotive coolers. The special welding paste achieves a high quality finish in the parts. After the welding paste is applied, the parts are treated with heat in an oven, that melts the paste and welds the components.

The paste needs to be applied accuracely. There is a high variabilty along the production process, because of the nature of this special paste. It needs to be calibrated after certain periods of time.

This operation was done previously by a skilled worker.

The robot introduces improvements in the process:

• repeatability
• cost save
• automatic paste calibration

Decuna developed this work under the "turnkey" concept. We dealt with mechanical design, supplier management, integration, production start and support all over the process.

Application video

The application can be seen in this video from different angles. A special tooling applies the paste in the inner side of the part, and the robot impregnates the outer side. The complete piece contour is covered with the robot arm movement and the paste nozzle.

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Decuna developed a welding cell with robot ready for different welding processes:

• MIG
  
• MAG
• TIG

The process combines welding with and without added material. A quick change in the tooling sets up the system for a different working configuration. Welding torch change is manual.

Our supply included a specific software, developed by Decuna, that allows the machine to work with 31 different references. The software also integrates the welding devices from two different manufacturers (Fronius and Sunarc)

Decuna implemented an automatic system to classify and store all the product references that our client had.

Therefore, there were prepared 18 classification lanes (2 lines for rejected products, and 16 that feed the palletting system).

A barcode system is used to classify the goods. As well, weight is also controlled in every product. 4 automatic palleting cells provide a cadence of 4000 boxes per hour.