These six-axis DRV90L7 articulated robots are capable of extremely precise, quick movements and have a hollow wrist that allows them to be easily combined with the correct tool for each production step.
METAL LS, the Bulgarian manufacturer of door locking systems, door and window handles, and building hardware started planning the new automated assembly of door locks in 2019. The robotic systems the company already used for other applications were too large for the planned production site, so the new solutions needed to be as compact and precise as possible, in addition to being state of the art.
Door and security locks are precision parts with standard dimensions and components stipulated in DIN standards. Therefore, quality and precision were critical deciding factors for METAL LS. The robots also needed to achieve high productivity — assembling between 10 and 14 locks per minute. Additionally, the company required a high level of flexibility from the solution and the possibility of retooling to reuse the same system to produce different types of locks in the future.
Following a comparison of various manufacturers and products, METAL LS opted for a robot system from Delta. It was the only manufacturer to offer a complete solution including programmable logic controllers (PLC), a human-machine interface (HMI), servo systems, and robotic arms with Machine Vision.
To implement this project, METAL LS and Delta collaborated to develop a custom workstation for the assembly of the mechanical door lock components. The main part of the system comprises a rotation table, on which seven six-axis DRV90L7 articulated robots are installed. The robots are capable of extremely precise, quick movements and have a hollow wrist that allows them to be easily combined with the correct tool for each production step. The DOP-115MX HMI is used to visualize all processes and enables the user to select various receipts for different locks through a touch screen. It also displays system information and alerts or alarms. The AS300-series (AS324MT-A) PLC monitors the assembly line, controls the ASDA B2 servo drive, and communicates with the servo drive on the rotating platform. Two DMV2000 Machine Vision image processing systems equipped with cameras are installed to localize components on the conveyor and send accurate signals to the robot allowing it to pick up and assemble the parts. The AC servo system comprising ASDA-A2 and ASDA-B2 drives and ECMA motors ensure that the robot arms are positioned precisely and that high productivity can be maintained.
To implement this project, METAL LS and Delta collaborated to develop a custom workstation for the assembly of the mechanical door lock components.
A few adjustments to the parameter settings were sufficient to quickly overcome initial communication problems between the PLC, robot, and the Machine Vision system. The careful preparation and system configuration carried out by the Delta team also ensured that all the Delta industrial automation (IA) products were soon integrated into the production processes.
Alongside the quality of the compact robotic system, METAL LS is thrilled with the sound advice and customer service it has received. The project was kicked off when the Field Application Engineering (FAE) team arrived on-site to support the construction of the assembly system together with Mechatronics, Delta’s Bulgarian partner. The assembly system is still undergoing tests, but initial results are already showing improved productivity and performance.
Delta EMEA
www.delta-emea.com
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