Steel enclosures for ATM machines are manufactured by this company. They utilize a PushCorp force compliant tool and a servomotor tool changer. The major objective of the system is to blend weld beads and remove splatter from the enclosure surface. The ATM enclosure is placed on a rotary table to allow the robot easy access to all of the sheet metal seams. As the grinding media is worn out, the robot cycles to the automatic disc dispenser for a new pad. This automated system has replaced a very time consuming dangerous manual operation.

This prototype system was converted into a six robot production cell at a Tier 1 auto glass manufacturer (the production line picture is confidential and is not shown here). The task of this cell is specifically to grind a smooth rounded profile on the edge of automotive sheet glass. Compliance is needed to maintain a continuous light force on the glass edge. The motor as well as the integrated grinding wheel are fluid cooled for continuous operation. This cell allows for mass production of auto glass with consistent quality edges.

A major first tier automotive supplier utilizes PushCorp tooling to prepare cast aluminum wheels for chrome plating. Due to the unforgiving nature of plating, all visible surfaces must be 100% scratch and blemish free. This system includes an active force device coupled with a servomotor tool changer to blend and smooth the surface. The process requires several different media types to handle all the complex surface features. This is a high volume operation with eight robots working continuously.

Heavy, stainless steel commercial kitchen kettles are polished in this cell. The process was previously slow and cumbersome due to the part size which caused an inconsistent finish on each kettle. Now, a robot does the polishing work using a PushCorp force compliance device and a high torque motor with tool changer. Cycle time for each kettle has been dramatically reduced. Surface finish consistency is noticeably better than manually finished kettles.

Die cast aluminum rack and pinion housings are now easily deburred at this Tier 1 manufacturer. Multiple robotic cells deburr the parting line and then transfer the housings to final cleaning. This finishing process was previously done manually and required approximately a dozen people. This is a simple, low cost system that is very efficient with excellent repeatability and quality.

Auto spoilers are finished with this high volume work cell at several different Tier 1 manufacturers. These blow molded plastic spoilers have flashing around the edges and need to be smoothed for priming and final paint. PushCorp force compliance tools carry motorized sanding drums for edge blending and DA sanders for the flat surfaces.

This Tier 1 manufacturer performs edge finishing on SMC (Sheet Molded Compound) automotive body panels. The process now utilizes a PushCorp force control tool coupled with a servomotor tool changer and inflatable sanding drum. The task of the work cell is to remove flashing from the edges of the panel as well as to radius the edges for better paint adhesion. The work cell has removed personnel from hazardous conditions and allowed for improved quality, repeatability and throughput.

This prototype system was converted into a production cell at a casting manufacturer (the production line picture is confidential and is not shown here). The component shown in the picture is a portion of a tire mold. The robotic process drills over 200 5mm diameter gating holes in the mold 100mm deep. In the past, deep drilling done by hand has resulted in misaligned holes and bit breakage. Using robotics and a PushCorp force control tool, bit life and position accuracy is dramatically improved.