Robot Artisan

Finishing system automates customization

Making whirlpool bathtubs out of thermoformed acrylic skin reinforced with fiberglass necessitates detail-oriented, labor-intensive processing. Customers increasingly demand customized luxury, style and high-quality standards—all at competitive prices. The finishing processes for unbatched products requires trim operators at Jason International Inc, North Little Rock, AR, to memorize and identify the trim patterns for over 50 different bath models. The process also introduces high levels of dust into the work environment.

Robotic Production Technology Inc, Auburn Hills, MI, was selected to design a robotic system to reduce cycle time while increasing quality and design flexibility. Robo Trim, a Fanuc robot integrated with a PLC, solves part fixture problems with a custom-designed universal part holding fixture. To meet the diverse number of trim operations, engineers integrated a tool changer with six spindles that accommodates drills, routers and saws. All tools are readily available to the robot during each machine cycle to maximize efficiency as it switches between drilling holes, cutting panels and trimming the perimeter of the composite parts. To accommodate part variation, a touch sensing capability locates part features and orientation to allow path program adjustments concurrently with dimensional tolerance inspection. Customized software handles multiple finishing tasks in a dissimilar line of products accurately and quickly. A bar coding system simplifies operator input because the robot can immediately recognize the code and apply the matching trim protocol program. The entire system is enclosed in a booth to control dust.

Within a few weeks of installing the Robo Trim routering system, Jason International experienced gains in speed, quality and overall productivity exceeding expectations; they anticipate recouping their investment ahead of initial estimates.—SG

For more information:

Circle 556-Robotic Production Technology Inc, or connect directly to their website via the Online Reader Service Program at www.RSLeads.com/110df-556

Circle 557-Jason International Inc, or connect directly at www.RSLeads.com/110df-557