Mesh Automation

Robotic Lathe and Press Tending

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Project Details

MESH designed, manufactured, integrated, and started up five robotic tending cells for the fabrication and polishing of galvanized aluminum reflector domes. The material flow started with a flat sheet of aluminum, which was punched, formed, and polished. An ABB IRB4600 robot with a MESH-designed dual jaw end-of-arm tool was used to pick, place, and tend the punch press. This sequence also included a punch lubrication step.

After punching the flat aluminum sheet, the robot removed the part from the press and loaded it into the forming lathe, where the dome was formed into its proper shape. Forming lubrication was applied by the robot before forming.

After forming, the robot selected another end-of-arm tool using an ATI tool changer. The aluminum dome was then presented to a MESH-designed pressure-compensated buffing station with a proprietary spray buffing compound application system. A custom rotating end-of-arm tool, designed and built by MESH, was used to pick, hold, and spin the aluminum dome during buffing.

The robot executed a custom buffing routine for the inside of the dome and then presented the dome flanges to a dual-wheel buffing wheel for final work. Automatic and consistent pressure compensation and buffing wheel diameter changes ensured quality. After completing the part, the robot placed the dome on an exit conveyor.

Final Project Outcome

  • Successful Implementation: Project was successfully implemented at the customer’s facility with a return on investment (ROI) of under 2.5 years.
  • ROI Drivers: Increased production volume, ergonomic and safety improvements, and labor savings.
  • Quality: No loss or degradation of finished goods quality.
  • Plant Management Improvements: Automation improved raw material sourcing and maintenance procedures, leading to better plant management.
  • Technical Skill Development: The customer’s first robotic automation project enhanced technical skills, improved staff training curriculum, and contributed to better worker satisfaction and efficiency in other areas of the facility.