A leading home appliance company, known for its wide range of products, excels in labor-intensive manufacturing. The introduction of automation equipment and robots has significantly improved efficiency, adaptability, and reliability in production. Especially suitable for automation, the repetitive and straightforward tasks on the production line are considered the ideal choice for optimization. Challenges in the Material HandlingLabor-intensive The reliance on manual labor for loading, unloading, and transportation tasks creates higher labor costs and poses challenges in managing the workforce. Monotonous work and physical fatigue The job positions frequently require repetitive motions and frequent turning, resulting in monotony for workers, leading to physical fatigue and reduced work efficiency. Waste of Workforce Employers' reliance on manual labor for these job positions results in a wasteful use of human resources and a higher employee turnover, necessitating continuous recruitment and training. Limitations of Spaces Traditional industrial robots may face limitations when deployed in confined spaces, but collaborative robots, known for their compactness and light weight, are more suitable for such environments. DUCO Automated Material Handing SolutionDuco Cobot GCR5-910, equipped with custom fixtures, is a versatile robot that performs various tasks at the assembly station. It excels at assembling panels, tightening them securely, and gripping workpieces with precision. During the transition to the unloading position, the robot skillfully flips the panels using its advanced end-of-arm movements. It then places the panels onto the buffer line, where they patiently await final product assembly. Unleashing Human Potential for Optimal Efficiency The introduction of robots has liberated artificial labor in this position, allowing displaced workers to be reassigned to non-automatable roles, maximizing the utilization of human labor. Higher Security and Reliability Eliminating manual intervention mitigates security risks between operators and frontend devices. Cost reduction and efficiency improvement. Robots' introduction achieves cost reduction and efficiency improvement, yielding ROI in around 1.5 years.
Traditional measurement methods such as gauges and coordinate measuring machines (CMM) are slow and limited in providing comprehensive data beyond contour dimensions, hindering tolerance inspections. Manual inspection methods are inadequate for modern technical requirements and production cycles. However, the emergence of automated 3D inspection in large industrial manufacturing companies will accelerate the advancement of automated inspection pipelines and workshops. By integrating robotized 3D inspection systems with assembly lines, unmanned and intelligent inspections can be achieved, leading to a transformative impact on intelligent manufacturing in World. Challenges in the Quality Inspection ProcessUncertainty in Detection Results Subjective evaluation by personnel introduces variability in the detection process, resulting in divergent detection outcomes and potential discrepancies among inspectors. Difficulty in Evaluating Detection Accuracy The absence of specific quantifiable detection data hinders the assessment of accuracy in detecting complex surfaces. Low Detection Efficiency The production of inspection fixtures, while necessary, can lead to longer manufacturing cycles, reduced flexibility, and increased production costs. DUCO Automated Quality Inspection SolutionDUCO Cobot utilizes integrated 3D laser scanning and measurement equipment to perform three-dimensional measurements on workpieces, acquiring surface data. By aligning the measurement model with the design model and extracting key features, it enables comparison with theoretical models, facilitating the identification of dimensions or defects. Furthermore, the DUCO Cobot can incorporate an intelligent rotating mechanism to automate rotation and support flexible fixtures, enabling comprehensive surface data capture from all angles. High Detection Efficiency Automated batch testing increases efficiency by more than 5 times. High Scanning Accuracy:Scanning accuracy can reach 0.025mm. Fast Measurement Speed Efficient data acquisition at a rate of 1.3 million times per second. Easy Deployment:Supports teaching and offline programming, secure networking, and easy deployment of machines with large motion trajectories. High Degree of Intelligence By simply pressing a button, you can automate and intelligently capture full-size data of injection molded parts quickly. Automatic Scanning and High-Efficiency Processing: The automated intelligent inspection system processes scanned data to generate complete 3D data by removing noise, aligning coordinates, and merging. Analysis of error data reports from batch inspections helps identify manufacturing process deficiencies, enabling timely modifications and optimizations to enhance product qualification rates.
Cobots excel in precise assembly tasks, providing a multi-fold increase in efficiency compared to manual labor. Equipped with versatile plug-and-play gripper modules, they can handle delicate assembly tasks in various industries, including electronics and appliances. Cobots are highly adaptable to flexible production environments, offering easy deployment, operation, and efficient layout changes. Challenges in the Assembly ProcessComponent Supply Chain Management Timely and accurate component supply is crucial in assembly to avoid production stagnation or delays caused by supply chain issues. Process Design and Tooling Development Process design and tooling development are essential for meeting different product assembly requirements, considering factors like assembly sequence, process flow, tooling design, and utilization within the assembly process. Quality Control Maintaining high-quality components is vital as it can directly impact the overall product quality, highlighting the importance of implementing effective quality control measures and inspection procedures throughout the assembly process. Change and Customization Demands As market demands shift and customization becomes more prevalent, assembly and manufacturing processes must adapt to meet the evolving requirements of diverse and personalized products. DUCO Automated Assembly Solution Medical Tubing Assembly, manually inserting one tube takes 10 seconds, and the production yield is low. By using the DUCO cobot, it only takes 3 seconds to complete, while significantly improving the production yield. Securing without being uncontrollable Assembly work demands specific skills, and it is crucial for new employees to receive training in order to enhance their productivity. DUCO plays a pivotal role in ensuring that the factory maintains control over capacity during periods of high production, thereby mitigating the risk of personnel uncertainties leading to uncontrollable situations. Effortless and Convenient Usage Collaborative robots, provide exceptional convenience and versatility in programming. They boast effortless learning and operation, enabling users to program them through intuitive drag-and-teach interfaces or user-friendly graphical interfaces. In contrast to traditional fixed automation devices, cobots excel in swift deployment and seamless transitioning between production lines. Rather than necessitating the rewriting of custom programs, cobot behaviors can be easily adjusted using modular software. This adaptability renders cobots exceedingly suitable for small batch flexible production scenarios.
Achieving specific torque or angle requirements is crucial for ensuring the appropriate fastening force of components. Manual operations carry the risk of accidental product damage, leading to increased costs in labor and components. However, collaborative robots can effectively tackle these challenges by precisely adjusting torque for each axis according to application requirements. With a payload range of 3-20 kg, they offer versatile solutions that cater to the diverse needs of various industries. Challenges in the Screwing ProcessHigh component costs Fragile components lead to higher costs due to potential damage during careless assembly by humans. Screwing Quality Insufficient manual screwing operations can lead to subsequent errors due to significant inaccuracies. Efficient Manual tasks often involve multiple workers collaborating to complete assembly and screwing operations. DUCO Automated Screwing SolutionDUCO Cobot incorporates cutting-edge robotic technology, featuring individual torque adjustment for each axis, thereby enabling highly flexible operations tailored to diverse scenario requirements. It boasts versatility across a broad spectrum of industries, including manufacturing, logistics, and the medical sector, effortlessly adapting its torque range to accommodate load demands spanning from 3 to 20 kilograms. Save production time and promote overall productivity improvement DUCO Cobot replaces three shifts of workers, providing cost savings, addressing recruitment challenges, and ensuring production stability, among other advantages. More security DUCO collaborative arm features safety functionalities and also helps businesses reduce production accidents. Controllable Quality The implementation of DUCO Cobot's automation not only mitigates human errors but also guarantees the consistently controlled quality of the products.
Automotive products are evolving to prioritize safety, energy efficiency, environmental friendliness, and pollution reduction. Adhesive usage in vehicle bodies is crucial and widely applied, serving various purposes such as sealing, shock absorption, rust prevention, sound insulation, and thermal insulation. These adhesive techniques provide an alternative to traditional welding methods, optimizing the production process. Therefore, selecting the appropriate welding adhesive is of utmost importance. Challenges in the Gluing ProcessLow Accuracy of Gluing Location The presence of irregular points on the component product hampers the precise positioning of manual gluing application, leading to reduced accuracy. Poor Worker Collaboration and Consistency Gluing task requires two manual operators: one loads and unloads materials, while the other applies adhesive with a glue gun. Poor Gluing Environment Handheld adhesive application equipment creates a disorganized and untidy work environment. DUCO Automated Gluing SolutionThe task involves using the DUCO Cobot with additional axis and an adhesive supply system, along with a safety laser scanner. A multi-collaborative robot, GCR20, equipped with a glue gun and tooling, is employed in the project. The robot follows a predetermined path for adhesive application while the operator handles part loading and clamping. Upon completion, the robot performs adhesive application at both workstations as instructed by the operator. Higher Security Protection The workstation incorporates advanced safety measures, including safety mats and laser scanners, to monitor the equipment's surroundings and provide access control, ensuring operator safety and enhancing overall personnel protection. Quality Assurance and Eco-Friendly Introducing an adhesive coating system that offers reliable, low-maintenance operation, consistent product quality, effective leak control, and environmental pollution prevention for long-term stability and ease of management. Higher ROI The calculation of customer shifts resulted in saving one operator, increasing efficiency by 15%, and achieving a 15-month return on investment.
Automobile manufacturing welding workshop emits welding fumes and intense arc light due to spot welding and carbon dioxide welding. Precision requirements of car body assembly lead to generation of grinding dust. Smoke and dust pollution in the workshop poses occupational health risks. Current practices concentrate welding and grinding in specific areas with purification treatments to reduce harmful substances and improve the working environment. Challenges in the Welding ProcessComplete residue cleanup Despite the use of purification and dust removal equipment during welding, a significant amount of welding slag and dust residue remains inside the white car body after completion, which cannot be completely cleaned. high-intensity work Residual cleaning of the vehicle's complex interior requires manual handheld vacuuming due to the presence of welding slag and dust, resulting in high labor intensity. Healthy The physical health of production workers has been significantly affected by the combination of high-intensity work and a heavily polluted workshop environment. Noisy Working with welding equipment is typically in a high-noise environment. DUCO Automated Welding Solution The project employs collaborative robots and low-noise vacuuming equipment for car interior cleaning. Two GCR-14 robots with vacuum cleaner attachments are stationed on each side of the production line. They follow a predetermined path to clean the interior and trunk, exiting afterward for the production line to proceed. Improved efficiency and sustainability The configuration of the DUCO cobot decreased the production cycle time from 62 to 50 seconds, facilitating future upgrades in the production line. Higher ROI The use of collaborative robots effectively resolved the hiring challenge for this position, achieving a 16-month ROI.
DUCO's palletiz stacking solution combines precision, speed, and reliability with the integration of collaborative robots, reducing physical strain on workers and enhancing workplace safety. The solution can be seamlessly combined with lift columns, allowing for efficient stacking of trays at varying heights. With easy deployment and intuitive controls, it optimizes the tray stacking process, streamlines operations, and improves overall efficiency, positively impacting productivity and employee well-being. Challenges in the Palletizing ProcessIrregular Shapes Some items may have irregular shapes that make it challenging to place them on a pallet. Weight and Stability Some items may be very heavy or prone to losing balance and stability during stacking. This can result in tilted pallets, item collapse, or unstable stacking. Space Utilization Efficiency Maximizing the utilization of pallet space is crucial in optimizing the loading process. DUCO AutomatedPalletizing SolutionThe DUCO palletizing kit provides an efficient solution for automated palletizing, featuring a vacuum gripper, lifting pillar, pallet detection sensor, and indicator for secure handling, precise positioning, and reduced errors. With its intuitive interface, the DUCO system allows for quick deployment of collaborative robots without coding knowledge, streamlining setup and launch within 20 minutes. Modular The DUCO palletizing kit provides a complete solution for efficient and automated palletizing, ensuring secure handling, precise positioning, and easy monitoring, for seamless integration into your workflow. Easy deployment DUCO system simplifies collaborative robot deployment by enabling non-coders to set up and launch robots in just 20 minutes, boosting productivity and efficiency without the need for complex programming or configuration. Simplified operations Real-time module-level performance adjustment optimizes operational parameters and configurations to maximize efficiency through continuous monitoring, instant adjustments, and iterative fine-tuning for improved system performance and productivity.
The traditional packaging industry heavily depends on manual labor, where humans are responsible for operating and handling products and packaging materials. This labor-intensive process requires physical effort and specific skills. However, manual labor is associated with limitations such as human errors, low efficiency, and constraints in working conditions. In contrast, automation in the packaging industry introduces machinery and equipment to streamline production processes. Challenges in the Packing ProcessHuman Resource Costs and Labor Shortages Traditional manual operations in the packaging industry impose high labor requirements and costs, leading to labor shortages and hindering production efficiency and timely product delivery. Human Errors and Quality Control Manual operations in packaging are prone to human errors like packaging mistakes, mislabeling, and inaccurate product stacking, resulting in quality problems, higher product return rates, increased customer complaints, and difficulties in maintaining consistent quality levels due to variations in employee skills and work habits. Production Efficiency and Capacity Limitations Manual operations in the packaging industry hinder production efficiency and capacity improvement due to their slower nature compared to automated processes. Flexibility and Adaptability Manual operations' fixed and repetitive nature poses challenges in responding to market demands and product changes. DUCO Automated Packaging SolutionDUCO Cobot operates autonomously, minimizing human intervention and maximizing production efficiency through preconfigured parameters. Its visual inspection system utilizes advanced camera technology and image processing to detect flaws and errors throughout packaging. These integrated systems automatically verify packaging accuracy, ensure precise labeling, and maintain product integrity, promptly addressing issues. DUCO Cobot also collects extensive production data and employs data analysis and optimization algorithms to continuously improve the packaging process. Higher Production Efficiency Automated packaging systems revolutionize packaging operations with high-speed, continuous, and precise processes, eliminating the need for manual intervention, resulting in increased production efficiency and shorter cycles. Reduced Labor Costs Automated packaging systems decrease reliance on manual labor, enabling resource allocation to higher-value tasks, reducing errors and accidents, and ultimately lowering labor costs and associated training expenses. Enhancing Packaging Quality With precise measurement and control of packaging materials, they minimize waste and excessive packaging, ultimately improving packaging quality and mitigating the risks of damage and contamination. Optimizing Inventory Management The automated packaging system can be integrated with inventory management systems to achieve real-time inventory monitoring and management.
Spraying and coating are surface finishing techniques used for coloring or protecting objects. Painting is widely used in automotive, furniture, architecture, and art. Spraying is typically used for large-scale, uniform coating. Manual operations present health and safety risks, while automated solutions provide better alternatives. Challenges in the Painting ProcessHealth and Safety Concerns Painting expose operators to chemicals, including VOCs and harmful particles, which can negatively impact their health with prolonged exposure. Painting Quality and Consistency Acquiring expertise and experience is essential for achieving exceptional spray coatings, as operators need to master proficient spraying techniques and skillfully adjust equipment to ensure consistent and high-quality results. Surface Preparation and Pre-Coating Treatment Prior to painting, surface preparation and pre-coating treatments are typically required, such as removing old coatings, cleaning, and sanding. Construction Efficiency and Cost Control Ensuring swift and efficient painting and coating is vital for large-scale projects and industrial applications, requiring operators to balance efficiency with coating quality, while also considering the costs involved in equipment and materials. DUCO Automated Painting SolutionThe utilization of DUCO cobots in painting or spraying operations yields notable benefits by enhancing the production rate, reducing operational costs, and minimizing material waste. These advanced cobots possess the capability to fully automate any painting process with exceptional precision. Equipped with multiple-axis arms, they offer unparalleled flexibility and precision, enabling them to effortlessly coat complex surfaces from any desired angle. Improving Quality and Consistency Automated systems ensure precise control over spraying and coating, resulting in consistent quality and uniform coverage for every workpiece, eliminating human errors and variability, and enhancing the overall quality of spraying and painting. Reducing Waste and Paint Material Consumption Automated systems can minimize waste and optimize paint distribution by accurately controlling the spraying volume and paint dispensing. Enhancing Workplace Safety Automated systems mitigate the potential health and safety risks faced by workers in spraying and painting tasks, by minimizing their exposure to hazardous chemicals and particles, thus improving overall workplace safety. Data Logging and Traceability Capability Automated systems offer the ability to record spraying and painting parameters for individual workpieces through data logging and traceability features.
GCR Series Cobot is equipped with an impressive selection of 16 TUV-certified safety features, which include advanced capabilities such as collision testing, force and power monitoring. Moreover, the Cobot is thoughtfully designed with integrated anti-static ESD protection on its body. This meticulous attention to safety ensures a heightened level of security in the collaboration between humans and robots, while also satisfying the specific requirements of various industries.
Multiple scene software packages are added (welding, palletizing, etc.); multiple external interface support (DI, DO, AI/O, etc.); support for cloud-based robot data monitoring and remote OTA upgrade; support for one-click deployment of multiple devices and remote data backup.
GRC Series cobot has a payload range of 25kg to 3kg and a radius range of 2000mm to 618mm, which enhances its performance and expands its applications. With precise motion control, high-speed operation, and seamless integration with other automation systems, this cobot can optimize productivity and streamline workflows in various industries.
Adopting modularized design, each functional module can be independently disassembled and replaced without the need for large-scale disassembly of the entire system. Supporting remote technical support, maintenance personnel can communicate with experts in real time through the network connection to obtain professional maintenance advice and guidance. In addition, its lightweight design enables it to be quickly deployed and adapted to various production lines.
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