Grinding: |
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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. |
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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. |
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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. |
Polishing: |
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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. |
Deburring: |
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This major motorcycle manufacturer utilizes a
PushCorp product to allow a previously slow and repetitive manual process to be automated. Cooling fins on a cylinder head are deburred
using a high-speed die grinder mounted to a PushCorp force compliance tool. This system enabled the manufacturer to increase throughput and
quality on a sensitive engine component. |
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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. |
Finishing: |
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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. |
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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. |
Drilling: |
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The prototype system shown here was converted
into a production cell at a major class 8 truck manufacturer (the production line picture is confidential). The cell utilizes a PushCorp
force control tool coupled with a servomotor tool changer. The cell is specifically designed for drilling and routing holes in truck cabs
as they progress down the assembly line. The drilled and routed holes are for mounting accessory lights, handles, etc. on the truck body.
This system allows the manufacturer to easily customize the truck to customer specifications. |
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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. |
Sanding: |
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A major motorcycle manufacturer utilizes PushCorp
tools for deburring, routing and finish sanding of saddlebags. The injection molded saddlebags are produced with flashing on the edges and
rough flat surfaces. Right and left robotic cells deburr the edges and drill mounting holes, before sanding the large surface areas with
light grit media. The prep work is accomplished using a high torque motor tool changer mounted on a PushCorp force compliance tool. The
work cell uses hard carbide bits and a shaft mounted orbital sanding disk. |
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This eight robot system was installed in an
automotive final assembly plant to wet sand the primer coat. Wet sanding eliminates orange peel and other surface defects to provide a
perfectly smooth surface for the color coat. This special technology unit was designed for the automotive industry but has crossed over
to other industrial segments. |
Machining: |
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This customer uses a standard cut-off saw for
machining an aluminum die cast part. A PushCorp high torque servomotor with tool changer is directly attached to the robot wrist with no
force tool, effectively turning the system into a low cost machining center. The cutting tool is a high-speed carbide tipped cut-off blade
that very efficiently trims the castings to size. This continuous process is no problem as the motor is water-cooled and the blades are
quick changed via the automatic collet. |
