Enhancing Efficiency with Automated Laser Robot Cell

EPIC Systems developed an innovative automated robotic solution to drive operational excellence, cost savings, and safety enhancements in manufacturing processes. By embracing cutting-edge technology, the customer positioned themselves for sustainable growth and competitiveness in the industry. 

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Hygienic Process System Design

Project

Overview

  • Industry: Hand Tool Manufacturing
  • Company Size: $500M
  • Location: USA
  • Customer Use Case: Hardening of Tool Cutting Edges

Customer’s

Challenge

A prominent hand tool manufacturer, with a diverse range of different tools in their portfolio, faced significant challenges in their heat-treating process. Their existing method relied on inefficient batch processing using a large oven, leading to energy wastage by heating the entire tool instead of just the localized cutting edge. This approach not only incurred high operational costs but also required a significant manpower to manage the batch processing setup. Moreover, the oversized footprint of the oven posed space constraints in the manufacturing facility, while also presenting safety hazards associated with operating large ovens. These challenges collectively hindered the manufacturer’s productivity and competitiveness in the market. 

 

  • Robotic Heat Treating Laser Allen-Bradley PanelView Plus

    Allen-Bradley PanelView Plus

  • Robotic Heat Treating Laser

    Robotic Heat Treating Laser

  • Robotic Heat Treating Laserline Control Panel

    Laserline Control Panel

Epic

Solution

EPIC Systems devised a state-of-the-art solution by introducing an automated laser robot cell to streamline the heat-treating process. A laser was mounted on the end of a robot arm, allowing precise and localized heating of the cutting edges of the hand tools. This eliminated the need to heat the entire tool, resulting in significant energy savings and enhanced efficiency. 

The integration of robotics enabled seamless and precise movement of the laser across the tools, ensuring uniform heat treatment with minimal human intervention. Additionally, EPIC’s team tailored the robot cell to suit the specific requirements of the hand tool manufacturer, optimizing performance and maximizing productivity.  

The automated system incorporated advanced safety features to mitigate hazards associated with traditional batch processing methods, ensuring a secure working environment for operators. 

Project

Impact

  • Enhanced Efficiency: The localized heating approach significantly improved process efficiency, reducing energy consumption and minimizing wastage. 
  • Cost Savings: By eliminating the need for batch processing and reducing manpower requirements, the customer achieved substantial cost savings in both operational expenses and labor costs. 
  • Optimized Space Utilization: The compact footprint of the automated system freed up valuable floor space, allowing for better utilization of manufacturing facilities. 
  • Improved Safety: The adoption of automated technology reduced the risks associated with manual operations and large ovens, ensuring a safer working environment for employees.
  • Quality Improvement: The precise and uniform heat treatment facilitated by the automated robotic system resulted in consistently high-quality hand tools, enhancing the customer’s reputation for reliability and durability. 

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Our Solutions

EPIC Systems is a multidisciplinary engineering integrator specialized in industrial automation for process manufacturers. We deliver solutions in the following areas:

Process Systems

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Machine Vision

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Robotics

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Industrial Automation

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