In the production of pistons, which requires mass manufacturing and involves various surface treatments, machining, boring, and milling processes, transporting the parts between different machines is a crucial step. This includes moving processed components to surface treatment areas and transferring qualified products into boxes. The transfer process between these stages is extensive, with some operations involving automatic loading and unloading that can be completed in as little as 8 seconds. However, manual handling remains labor-intensive, inefficient, and prone to errors such as improper installation or damage to the piston surfaces.
To address these challenges, many piston manufacturers have turned to automation solutions, such as the palletizing robots produced by Germany's Baigra. These systems not only improve efficiency and output but also enhance product quality and economic benefits. One such example is the MS600 standard palletizing robot used by Federal Mogul in St. Lunburg, Germany.
The MS600 is composed of several key mechanisms: a feeding system, an unloading mechanism, a pallet handling unit, and a two-dimensional XZ robot. It can load and unload parts from the machine every 8 seconds and complete a pallet exchange in just 7 seconds, demonstrating high operational efficiency.
The feeding mechanism consists of a manual trolley equipped with 12 steel mesh baskets, each containing 15 pistons. Each basket measures 545 × 310 × 95 mm and weighs approximately 350 grams per piston. A full trolley holds 180 pistons, totaling around 63 kg. When the trolley is pushed into the feeding rail, the system automatically lifts the top tray and moves it for processing.
The unloading mechanism functions similarly but handles empty carts once the parts are processed. After all the pistons on a tray have been handled, the cart is manually removed and replaced with an empty one.
The pallet handling mechanism includes two vertical lifting shafts and a horizontal transport axis, all controlled by servo motors. The two-dimensional XZ robot, designed specifically for vertical CNC machines, uses a 4-finger gripper with positioning assistance to handle the pistons efficiently. The X-axis has a stroke of 1.2 meters, while the Z-axis covers 0.4 meters, allowing for fast and precise movements.
The control system of the MS600 utilizes Baigra’s TLCC CAN bus system, which coordinates the movement of all axes through a centralized controller. Servo motor drives and precision planetary reducers ensure smooth and accurate operation.
Baigra’s palletizing robots are widely used across various industries, including automotive, electronics, and consumer goods. Their Cartesian-based design makes them simple, cost-effective, and highly efficient. With over 20 years of experience, Baigra has developed thousands of similar systems, offering more than 10 types of automated loading and unloading solutions to meet diverse industrial needs.
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