3/31/2022
Delta’s Machine Vision Robotic Solution Helps Metal LS Build Precise, Quick, and Flexible Assembly Lines
Metal hardware is a common component of our daily lives. It is used for cylinder locking systems, door handles, windows, furniture and more. During production it becomes durable and is fabricated through casting, forging, polishing, and assembly procedures. However, with rising demand and the trend for small-volume large-variety production, conventional manufacturing methods have not been able to keep up. Manufacturers have started to seek new solutions using smart manufacturing that features high speed, high precision, and flexibility to meet market growth.
The Bulgarian hardware manufacturer, Metal LS, was looking for solutions. As one of the world's biggest manufacturers of cylinder locking systems and hardware handles, Metal LS started to plan a new automated assembly for door locks in 2019. Considering that the original systems were too large for the new production site, Metal LS needed a solution with a compact design that could assemble 10 to 14 locks per minute. Apart from the size and speed, it was equally important that the solution met local standards of high precision and flexibility to retool for different product types. After a comprehensive evaluation, Metal LS opted for Delta's robotic system. The co-developed customized workstation integrated Delta's PLC, HMI, servo system, industrial robot, and machine vision system, which completely fulfilled the requirements for speed, precision, and flexibility.
Metal LS adopted Delta’s Machine Vision Robotic Solution where the Compact Modular Mid-range PLC AS 300 Series controls the Servo System ASDA-B2 Series and the rotation table. Operators can select different assembly recipes for different types of locks. The Machine Vision System DMV2000 Series localizes components on the conveyor and sends accurate signals for the Servo System ASDA-A2 / ASDA-B2 Series to drive the Articulated Robot DRV90L7 Series for precise pick and place and high productivity.
Delta’s Machine Vision Robotic Solution has the following features:
- Highly integrated for quick adjustments
Delta’s Machine Vision Robotic Solution integrates Delta’s industrial automation products to offer full-range solutions from a single source. The communication between Delta’s PLC, industrial robot, and machine vision system is smooth and parameter settings and adjustments are easy and quick, which accelerates adoption.
- Global Service and professional consultants
Delta has worldwide customer service and technical teams based on five continents to give advice and support timely troubleshooting for local customers. During the project for Metal LS, Delta’s field application engineering (FAE) team arrived on-site for assembly system construction support with the local partner, Mechatronics. With their dedication, the initial results showed significant productivity improvements.
- Flexible production for small-volume large-variety production
The solution employs Delta’s Articulated Robot DRV90L7 Series. Besides fast and precise movements, the robot features a hollow wrist design that allows retooling for flexible and large-variety production.
Delta’s Machine Vision Robotic Solution meets the requirement of Metal LS with its compact design. It also fits their goals and increases both precision and speed for better productivity and quality through clear discussion and on-site evaluation before implementation. Moreover, the solution adopted the idea of small-volume large-variety production for smart manufacturing and plans for flexibility for future use to enhance completeness.
Metal LS adopted the Machine Vision Robotic Solution integrating PLC, HMI, servo system, industrial robot, and machine vision system in one stop to achieve high-speed, high-precision, and flexible production.