Combining 3D machine vision, six-axis robotics, and custom tooling to automate the handling of heavy, randomly oriented parts.
At a truck and axle manufacturing plant in North Carolina, operators manually unloaded heavy, irregular components from large bins before transferring them to a re-gripping station. Individual axle and brake components could weigh up to 25 pounds, creating a repetitive and physically demanding material-handling task.
Concept Systems developed a random bin picking system combining 3D machine vision, six-axis robotics, custom software, and application-specific end-of-arm tooling to automate the process.
The Problem: Picking Heavy, Randomly Oriented Parts
Operators were required to reach into 42-by-48-inch bins up to 30 inches deep and remove irregular truck axle and brake components one at a time. Parts measured up to 20 inches long and weighed as much as 25 pounds, with overlapping components sometimes requiring workers to manipulate significantly more weight.
The random arrangement made the process especially challenging to automate. Parts could overlap, shift after every pick, and appear in different positions and orientations throughout the bin. Components near the bottom and corners of the container further limited the angles available for gripping and removal.
The manufacturer needed a solution that could reliably identify and retrieve individual parts while reducing the repetitive manual handling required of operators.
The Solution: 3D Vision-Guided Random Bin Picking
Concept Systems integrated an ABB six-axis robot, SICK PLB 3D vision system, custom software, and purpose-built end-of-arm tooling to create an automated random bin picking system.
Unlike structured picking applications, the robot cannot rely on predetermined part positions. Each successful pick changes the arrangement of the remaining components, requiring the system to reevaluate the bin and determine a new approach.
Seeing the Bin in 3D
The SICK PLB vision system uses laser scanning and a camera to capture the three-dimensional geometry of the parts within the bin. The resulting X, Y, and Z coordinates create a point cloud that allows the system to determine the position and orientation of potential parts for picking.
Because the system uses 3D scanning rather than conventional image contrast, it can operate across varying lighting conditions without requiring specialized application lighting.
Planning Each Robotic Pick
Using the vision data, Concept Systems’ software determines an appropriate part and generates the information required for the robot to complete the pick.
The six-axis ABB robot provides the range of motion needed to reach components in difficult locations, including parts positioned near the walls and corners of the bin. Concept Systems developed rules governing allowable grips and robot movements to help prevent collisions between the robot, tooling, parts, and bin.
Custom end-of-arm tooling allows the robot to securely handle the irregular components before transferring them to the next stage of production.
The Results
The completed random bin picking system automated a physically demanding material-handling process while providing the flexibility required for constantly changing part positions.
- Achieved a 25-second pick-to-pick cycle
- Reduced manual handling of heavy and irregular components
- Removed operators from the repetitive bin-unloading process
- Improved bin picking speed and consistency
- Adapted to changing part positions after every pick
- Operated across varying plant lighting conditions
- Enabled continuous automated operation
The system was engineered and implemented in just two months by two Concept Systems engineers working with three client engineers.
Automate complex material handling with robotics, 3D machine vision, and application-specific tooling engineered around your process.
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Project Details
Project Duration
2 Months
Team
Client: 3 engineers
Concept Systems: 2 engineers
Technology Used
- ABB IRB 6640 Six-Axis Robot
- SICK PLB 3D Vision System
- 3D Laser Scanning
- Custom End-of-Arm Tooling
- Concept Systems Custom Software