Pistons are components that require mass production and undergo various processes such as surface treatment, machining, boring, and milling throughout the entire manufacturing cycle. During these steps, pistons must be transported between different machine tools, then moved to surface treatment areas, and finally placed into boxes once they are qualified. The transfer of pistons between these stages is a significant task, and in some cases, even with automated loading and unloading, the process can take as little as 8 seconds. This manual work is labor-intensive, inefficient, and prone to errors—such as misalignment or damage to the piston surfaces. To address these challenges, many piston manufacturers have turned to palletizing robots from Germany's Baigra, which not only enhance productivity and output but also improve product quality and economic returns.
As an example, this article introduces the standard palletizing robot model MS600 by Baigra, which is used by Federal Mogul in St. Lunburg, Germany. The MS600 consists of several key components: a feeding mechanism, a blanking mechanism, a pallet handling mechanism, and a two-dimensional handling robot. It operates at a high speed, completing part loading every 8 seconds and pallet exchange in just 7 seconds. Below, we explore the main components of the MS600 in detail.
The feeding mechanism includes a manual trolley and a tray lifting section. The trolley holds 12 steel mesh baskets filled with pistons, each containing 15 pistons weighing approximately 350 grams. A full trolley carries 180 pistons, totaling around 63 kg. These baskets are stacked neatly and securely during manual transport. When the trolley is pushed into the system, it aligns with a specific sensor, allowing the system to recognize the position and begin the transfer process. After processing, the empty trolley is manually removed, and a new one is inserted.
The unloading mechanism functions similarly but is designed for empty trolleys. Once all the pistons on the feeding trolley are processed, the trays are moved to the unloading area, where they are manually taken away and replaced with an empty trolley.
The pallet handling mechanism comprises two vertical lifting shafts and a horizontal transport shaft. These axes are driven by servo motors and controlled through a precise system, enabling smooth and accurate movement of the trays.
The two-dimensional XZ robot handles the actual picking and placing of the pistons. It uses a four-finger gripper with auxiliary positioning to ensure secure and accurate handling. The robot has an X-axis stroke of 1.2 meters and a Z-axis stroke of 0.4 meters, with maximum speeds of 2 m/s and 1 m/s respectively.
The control system of the MS600 is based on Baigra’s TLCC CAN bus system, which ensures seamless communication between the master station and multiple slave stations. Each axis is driven by a high-precision servo motor, and the planetary reducers used are from Neugart, known for their reliability and precision.
In summary, the MS600 palletizing robot significantly improves efficiency, reduces labor costs, and enhances product quality in piston manufacturing. Baigra offers similar systems for various machining processes, including turning, milling, and grinding, making them ideal for industries such as automotive, consumer goods, and electronics. With over 20 years of experience, Baigra has produced thousands of such robots, proving their value in modern manufacturing environments.
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