November 2024 Volume 6

AUTOMATION

TRANSFORMING BILLET HANDLING WITH FLEXIBLE 3D ROBOT VISION By Rob Mertens

T raditional forging processes have long been hampered by inefficient and labor-intensive billet feeding methods. Manual feeding, while reliable, is physically demanding and dangerous. Mechanical feeders, while automated, are often bulky, noisy, and costly to maintain. In recent years, advancements in robotics and computer vision technology have opened up new possibilities for optimizing the forging process. Pickit 3D has pioneered a solution that leverages 3D robot vision to automate billet handling, offering significant benefits in terms of efficiency, productivity, and cost effectiveness. This article explores how 3D robot vision-based billet handling works and the essential components needed to imple ment this innovative technology in a forging facility. Why 3D Robot Vision Benefits the Forging Industry Truly flexible billet handling is enabled by 3D robot vision. This technology equips robots with the ability to "see" their surroundings, interpreting the three-dimensional world in real-time. By capturing and analyzing visual data from 3D vision cameras, robots can accurately identify the size, shape, posi tion, and orientation of, for example, billets within a bin. This visual intelligence enables robots to perform tasks with precision and flexibility. Unlike traditional mechanical systems that are limited to predetermined movements,

3D robot vision allows robots to adapt to variations in billet size, shape, and orientation, ensuring consistent and reliable handling. This flexibility is key in a market demanding more diverse products, with high-mix, low volume production becoming increasingly important. Traditional automation systems struggle to adapt to rapid changes, while 3D robot vision systems excel in such environ ments. Their versatility allows them to handle different objects and processes with ease and without major interventions. Moreover, by eliminating the need for bulky mechanical feeding mechanisms, 3D robot vision-based systems can reduce space requirements and minimize the risk of equipment failures. This not only improves efficiency but also enhances safety within the forging facility. And lastly, the forging industry faces a lack of skilled labor. Repetitive and simple tasks strain human resources and hinder productivity. 3D robot vision offers a solution by auto mating these monotonous tasks and creating a safer and more ergonomic environment. This frees up valuable human workers, allowing them to focus on higher-value activities that require human expertise and creativity, and significantly decreases incidents related to material handling. Essential Components for 3D Robot Vision Guided Billet Handling To implement a 3D robot vision-based billet handling system, forges need a few key compo nents. The first is a robust industrial robot, capable of operating in the demanding environ ment of a forge. Leading brands like Fanuc, ABB, KUKA, and Yaskawa are all compatible with Pickit 3D robot vision. Next, you’ll need a 3D robot vision solution that comprises hardware and software. Pickit 3D offers a fully standardized solution consisting of a Pickit 3D Billet Picker gripper and 3D camera, which can either be robot or stationary mounted. These are fully integrated and supported by the Pickit 3D software platform, including a complete end-of-arm tool model and a pre-configured vision engine for billets.

Finally, it is wise to involve a specialized automation partner that knows how to implement a 3D robot vision system right from the first time. Pickit 3D, for example, has several projects running at US and European forges, commissioned with the support of dedicated partners that know the forging industry. For the North American market specifically, Pickit 3D partners with Lasco Engineering Services, a long-standing name in the forging industry, as well as other integrators such as CIM systems.

Pickit 3D offers a fully standardized solution consisting of a Pickit 3D Billet Picker gripper, with a 3D vision camera and software

FIA MAGAZINE | NOVEMBER 2024 20